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Home >> Chevrolet >> 2012 >> Caprice 3.6 3 >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls/Fuel - 3.6L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure
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Removal Procedure

  1. Ignition OFF.
    2. WARNING:

    Refer to Battery Disconnect Warning .

  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Primary) , Battery Negative Cable Disconnection and Connection (Auxiliary) .
    3. WARNING:

    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

    WARNING:

    Refer to Safety Glasses Warning .

  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    4. WARNING:

    Refer to Gasoline/Gasoline Vapors Warning .

  4. Relieve the low side fuel pressure. Refer to Fuel Pressure Relief (High Pressure) , Fuel Pressure Relief (Low Pressure) .
  5. Drain the fuel tank. Refer to Fuel Tank Draining .
  6. Remove the right rear wheel. Refer to Tire and Wheel Removal and Installation .
  7. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  8. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Except 4L60) .
  9. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement .
  10. Remove the parking brake rear cables. Refer to Parking Brake Rear Cable Replacement (9C3) , Parking Brake Rear Cable Replacement (9C1) .
  11. Remove the rear stabilizer bar. Refer to Stabilizer Shaft Replacement .
  12. Disconnect the fuel feed line pressure sensor connector. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe .
    13. Fig 1: EVAP Pipe And Fuel Tank Filler Vent Pipe
    GM2661049Courtesy of GENERAL MOTORS COMPANY
  13. Disconnect the EVAP pipe (1) from the fuel tank filler vent pipe.
  14. Loosen the filler tube clamp (1) at the filler tube.
    15. Fig 2: Identifying Fuel Feed Line & Fuel EVAP Hose
    GM1949815Courtesy of GENERAL MOTORS COMPANY
  15. Using the 7370  separator remove the EVAP pipe (2) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  16. Using the 7371  tool remove the fuel feed pipe (1) from the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    17. Fig 3: Fuel Tank Electrical Connector
    GM2084586Courtesy of GENERAL MOTORS COMPANY
  17. Disconnect the fuel tank assembly electrical connector (1) from the chassis electrical harness.
    18. Fig 4: Supporting Rear Frame Assembly
    GM2172065Courtesy of GENERAL MOTORS COMPANY
  18. Support the rear frame assembly (1) using a suitable tool (2).
    19. Fig 5: Rear Frame And Chassis Retaining Bolts
    GM2661187Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    The rear frame to chassis retaining bolts are single use items and must be replaced with NEW bolts.

  19. Remove the rear frame to chassis retaining bolts (1) and discard.
  20. Remove the rear frame to chassis retaining bolts (2) and discard.
    21. Fig 6: Rear Frame Bolts
    GM2178933Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Make sure that the EN-48536  tool bolts (2) extends 50 mm (2 in) from the rear frame.

  21. Install the EN-48536  tool to the rear frame mounts (1).
    22. NOTE:

    When lowering the rear frame do not to damage the rear brake hoses.

  22. Lower the rear frame onto the frame support tool EN-48536 (2).
    23. Fig 7: EVAP Emission Canister
    GM2661194Courtesy of GENERAL MOTORS COMPANY
  23. Remove the EVAP emission hoses from the EVAP emission canister (3). Refer to Plastic Collar Quick Connect Fitting Service .
    24. Fig 8: Identifying Fuel Tank Strap To Chassis Retaining Bolts
    GM1949817Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Do not to damage the following components when lowering the fuel tank assembly.

    • The fuel tank assembly wiring harness.
    • The fuel feed pipe.
    • The EVAP pipes.
    NOTE:

    Support the fuel tank assembly while removing the fuel tank assembly retaining straps to chassis retaining bolts (1)

  24. Remove the fuel tank assembly retaining straps to chassis retaining bolts (1).
  25. With the aid of an assistant, carefully manoeuvre the fuel tank assembly from the vehicle.
  26. If the fuel tank is to be replaced, remove the following components.
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