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Home >> Chevrolet >> 2004 >> Impala SS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System 3.8L (Introduction) >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
IMPORTANT: Always maintain cleanliness when servicing the fuel system components.
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer toLifting and Jacking the Vehicle in General Information.
  4. Loosen the fuel filler hose clamp (1) at the fuel tank (3).
    5. Fig 1: Identifying Fuel Tank Components
    GM186674Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank filler hose from the fuel tank.
    6. Fig 2: Fuel Tank Filler Hose
    GM155468Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed and the fuel return pipes at the fuel filter area. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    7. Fig 3: Disconnecting Fuel Feed & Fuel Return Pipes
    GM32401Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the evaporative emission (EVAP) pipe from the connection at the front of the fuel tank.
  8. Remove the rubber exhaust pipe hangers in order to allow the exhaust system to drop slightly.
  9. Separate the EVAP fresh air hose at the splice.
    10. Fig 4: Separating EVAP Fresh Air Hose
    GM698635Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel tank shield push pins (2).
  11. Remove the fuel tank shield (3).
  12. Install a transmission jack to the fuel tank (1).
    13. Fig 5: Removing Fuel Tank Shield
    GM699555Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not bend the fuel tank straps as this may damage the straps.
  13. Remove the fuel tank strap bolts (2) from the fuel tank straps (3).
  14. Remove the fuel tank (1) from the vehicle.
  15. Place the fuel tank in a suitable work area.
    16. Fig 6: Removing Fuel Tank
    GM699556Courtesy of GENERAL MOTORS CORP.
  16. Remove the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  17. Remove the fuel feed, the fuel return, and the EVAP pipe assemblies.
    18. Fig 7: View OF Fuel Tank & EVAP Canister
    GM531026Courtesy of GENERAL MOTORS CORP.
  18. Remove the insulator pad from the fuel tank. Note the location of the insulator pad for the installation.
    19. Fig 8: Removing Insulator Pads
    GM12743Courtesy of GENERAL MOTORS CORP.
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