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Home >> GMC >> 2009 >> Envoy 4.2 S, 4WD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System & Fuel System - 4.2L - Introduction >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure

Removal Procedure

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH-48027)  or Fuel Pressure Relief (With CH 48027) .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Remove the frame brace. Refer to Frame Brace Replacement .
  4. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement .
  5. Drain the fuel tank. Refer to Fuel Tank Draining .
    6. Fig 1: Locating Evaporative Emission (EVAP) Canister Fresh Air Pipe
    GM1480088Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the evaporative emission (EVAP) canister fresh air pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the EVAP canister solenoid pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the EVAP purge pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 2: Locating Fuel Filler Pipe Recirculation Hose At Fuel Tank
    GM1480087Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel filler pipe recirculation hose from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Loosen the clamp securing the fuel fill pipe to the fuel tank.
  11. Disconnect the fuel fill pipe from the fuel tank.
    12. Fig 3: Identifying Fuel Feed Pipe & EVAP Pipes
    GM1368522Courtesy of GENERAL MOTORS CORP.
  12. Disconnect the fuel feed pipe (2) and EVAP pipe (1) from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
  14. Support the fuel tank.
    15. Fig 4: Removing/Installing Fuel Tank Straps
    GM1480086Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Damage to Fuel Tank Straps Caution .
  15. Remove the fuel tank strap attaching bolts.
  16. Remove the fuel tank straps.
  17. Carefully lower the fuel tank.
    18. Fig 5: View Of Connections On Top Of Fuel Tank
    GM1480091Courtesy of GENERAL MOTORS CORP.
  18. Disconnect the EVAP vent valve electrical connector (8).
  19. Disconnect the fuel tank pressure sensor electrical connector (2).
  20. Disconnect the fuel sender electrical connector (1).
  21. Remove the fuel tank.
  22. Place the fuel tank in a suitable work area.
  23. If the fuel tank is not being replaced, go to the Installation Procedure .
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