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Home >> Chevrolet >> 2010 >> HHR SS, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.0L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

WARNING: Refer to Gasoline/Gasoline Vapors Warning .
CAUTION: 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.
    Fig 1: Fuel Tank Vent Pipe Quick Connect Fittings
    GM1636704Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (High Pressure Side)  or Fuel Pressure Relief (Without CH 48027)  or Fuel Pressure Relief (With CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (Non E-85) .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel tank vent pipe quick connect fittings (1, 4). Refer to Plastic Collar Quick Connect Fitting Service .
  5. Loosen the fuel fill pipe hose clamp (2) at the fuel tank.
  6. Remove the fuel fill pipe hose from the fuel tank.
    7. Fig 2: Fuel Tank Electrical Connector
    GM1636801Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel tank electrical connector (1) from the pass thru connector.
    8. Fig 3: Exhaust Pipe Insulators
    GM1631769Courtesy of GENERAL MOTORS CORP.
  8. Remove the exhaust pipe insulators from the underbody hangers.
  9. Remove the muffler insulators from the underbody hanger and slowly lower the exhaust in order to allow it to rest on the rear axle beam.
    10. Fig 4: Fuel Tank & Straps
    GM1636706Courtesy of GENERAL MOTORS CORP.
  10. Place an adjustable jack under the fuel tank.
  11. Remove the fuel tank strap bolts.
  12. Remove the fuel tank straps.
  13. Using the adjustable jack, carefully lower the fuel tank away from the vehicle.
  14. With the aid of an assistant, place the fuel tank on a suitable work surface.
    15. Fig 5: Fuel Tank Vent Pipe
    GM1636693Courtesy of GENERAL MOTORS CORP.
  15. If replacing the fuel tank perform the following steps, remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    16. Fig 6: Fuel Feed Intermediate Pipe
    GM1636696Courtesy of GENERAL MOTORS CORP.
  16. Remove the fuel feed intermediate pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    17. Fig 7: Fuel Tank Vent Pipe
    GM1636697Courtesy of GENERAL MOTORS CORP.
  17. Remove the fuel tank vent pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    18. Fig 8: Fuel Tank Electrical Harness
    GM1636804Courtesy of GENERAL MOTORS CORP.
  18. Disconnect and remove the fuel tank electrical harness.
  19. Remove the fuel tank module. Refer to Fuel Pump Module Replacement .
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