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Home >> Cadillac >> 2011 >> DTS 4.6 S >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 4.6L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: Identifying Fuel Fill Hose Clamp
    GM1671746Courtesy of GENERAL MOTORS COMPANY
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (CH 48027) , Fuel Pressure Relief (Without CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the left rear wheel house liner. Refer to Rear Wheelhouse Panel Liner Replacement .
  4. Using compressed air, blow any dirt and/or debris from around the fuel fill pipe and evaporative emission (EVAP) line connections.
  5. Loosen the fuel fill hose clamp (1) at the fill pipe.
    6. Fig 2: Identifying Fuel Tank EVAP Recirculation Line Quick Connect Fitting
    GM1671747Courtesy of GENERAL MOTORS COMPANY
  6. Disconnect the fuel fill hose (2) from the fuel fill pipe.
  7. Disconnect the fuel tank EVAP recirculation line quick connect fitting (1) from the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service .
    8. Fig 3: Identifying Automatic Level Control Sensor Link
    GM1706922Courtesy of GENERAL MOTORS COMPANY
  8. Disconnect the automatic level control sensor link from the left rear suspension control arm, if equipped.
    9. Fig 4: Identifying Electronic Suspension Front Position Sensor Link
    GM1665080Courtesy of GENERAL MOTORS COMPANY
  9. Disconnect the left and right electronic position sensor links from the ball studs (1). Regular production option (RPO) F55 shown, F38 similar.
    10. Fig 5: Identifying Fuel Fill Pipe Vent Line & Fuel Tank Vapor Line Quick Connect Fitting
    GM1671749Courtesy of GENERAL MOTORS COMPANY
  10. Disconnect the fill pipe vent line (2) and the fuel tank vapor line (3) quick connect fittings from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 6: Identifying Fuel Feed Rear Pipe Quick Connect Fitting
    GM1671750Courtesy of GENERAL MOTORS COMPANY
  11. Disconnect the fuel feed line quick connect fitting (1) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    12. Fig 7: Identifying Fuel & EVAP Line Retainer
    GM1671751Courtesy of GENERAL MOTORS COMPANY
  12. Remove the fuel and EVAP line retainer (1) from the side rail.
    13. Fig 8: View Of Fuel Tank Harness Electrical Connector & Clips
    GM1671752Courtesy of GENERAL MOTORS COMPANY
  13. Disconnect the body harness electrical connector from the fuel tank harness electrical connector (1).
  14. Remove the fuel tank harness clips (2, 3) from the rear compartment side rail.
  15. Remove the exhaust system. Refer to Exhaust System Replacement .
    16. Fig 9: View Of Rear Brake Hose Bracket
    GM1671753Courtesy of GENERAL MOTORS COMPANY
  16. Loosen the left and right rear brake hose bracket nut and slide the stud out of the keyhole slot in the side rail.
    17. Fig 10: Identifying Rear Shock Bolts
    GM1671754Courtesy of GENERAL MOTORS COMPANY
  17. Remove the rear shock bolts.
  18. Support the front of the vehicle with a jack stand at the engine cradle.
  19. Support the rear suspension crossmember with a suitable adjustable jack.
    20. Fig 11: Locating Rear Suspension Crossmember Bolts
    GM1671755Courtesy of GENERAL MOTORS COMPANY
  20. Remove the rear suspension crossmember bolts.
    21. Fig 12: Identifying Rear Suspension Crossmember
    GM1671757Courtesy of GENERAL MOTORS COMPANY
  21. Using the adjustable jack (1), slowly lower the rear suspension crossmember allowing the crossmember to pivot at the front bolts, until the rear springs can be removed.
  22. Remove the rear coil springs.
    23. Fig 13: Identifying Rear Suspension Crossmember, Fuel Tank Straps & Bolts
    GM1671758Courtesy of GENERAL MOTORS COMPANY
  23. Remove the fuel tank strap bolts.
  24. Remove the fuel tank straps.
  25. Remove the fuel tank.
  26. Place the fuel tank on a suitable work surface.
    27. Fig 14: Identifying Fuel Tank Electrical Harness Connectors
    GM1671759Courtesy of GENERAL MOTORS COMPANY
  27. Disconnect the fuel tank electrical harness connectors from the module and pressure sensor.
  28. Remove the electrical harness (1).
    29. Fig 15: Identifying Fuel Feed Line Quick Connect Fitting
    GM1671760Courtesy of GENERAL MOTORS COMPANY
  29. Disconnect the fuel feed line quick connect fitting from the module. Refer to Plastic Collar Quick Connect Fitting Service .
  30. Remove the fuel feed line from the retaining feature in the fuel tank.
  31. Remove the fuel feed line.
    32. Fig 16: View Of Fuel Feed Line
    GM1671761Courtesy of GENERAL MOTORS COMPANY
  32. Install the J 45722 to the lock ring.
    33. Fig 17: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS COMPANY
    CAUTION:

    Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

    CAUTION:

    Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

    NOTE:
    • The fuel module assembly may spring up from its position.
    • When removing the fuel module assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel module assembly O-ring seal and replace it with a new one.
    • Carefully discard the fuel in the reservoir bucket into an approved container.
    NOTE:

    Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

  33. Use the J 45722 and a long breaker bar in order to unlock the fuel module lock ring. Rotate the lock ring in a counterclockwise direction.
    34. Fig 18: View Of Fuel Pump Module
    GM1671762Courtesy of GENERAL MOTORS COMPANY
  34. Remove the J 45722 and the fuel module lock ring.
  35. Slowly raise the module until the fuel level sensor float arm is just visible.
    36. NOTE:

    When removing the module from the fuel tank, be aware that the reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

  36. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  37. Carefully discard the fuel in the module bucket into an approved container.
    38. NOTE:

    DO NOT reuse the old fuel pump module seal.

  38. Remove and discard the fuel pump module O-ring seal.
    39. Fig 19: Checking Lock Ring For Flatness
    GM1617750Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • Some lock rings were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.
    • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.
    • Check the lock ring for flatness.
  39. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 different points.
  40. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  41. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
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