Envoy, Rainer, Trailblazer 2006-2007

Removal & Installation

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Extended Wheelbase Models



  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle securely on jackstands.
  6.  
  7. Remove the 2 mounting bolts from the frame brace and remove the frame brace from the frame.
  8.  
  9. Remove the fuel tank shield to the frame retaining bolts and nut, then remove the fuel tank shield from the frame.
  10.  
  11. Drain the fuel tank as follows:
    1. Loosen the fuel fill hose clamp.
    2.  
    3. Disconnect the fuel fill hose from the fuel tank.
    4.  
    5. Use a hand or air operated pump device in order to drain as much fuel from the fuel tank as possible.
    6.  

  12.  
  13. Loosen the fuel hose clamp at the fuel tank.
  14.  
  15. Separate the fuel hose from the fuel tank.
  16.  
  17. Disconnect the fuel feed pipe (1) and evaporative emission (EVAP) pipe (2).
  18.  
  19. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
  20.  
  21. With the aid of an assistant, support the fuel tank.
  22.  
  23. Remove the fuel tank strap bolts.
  24.  
  25. Remove the fuel tank straps.
  26.  
  27. Carefully lower the fuel tank.
  28.  
  29. Disconnect the fuel tank pressure sensor electrical connector.
  30.  
  31. Disconnect the EVAP vent valve electrical connector.
  32.  
  33. Disconnect the fuel tank module electrical connector.
  34.  
  35. Remove the fuel tank.
  36.  
  37. Place the fuel tank in a suitable work area.
  38.  

To install:

  1. With the aid of an assistant, position and support the fuel tank.
  2.  
  3. Connect the fuel sender electrical connector.
  4.  
  5. Connect the fuel tank pressure sensor electrical connector.
  6.  
  7. Connect the EVAP vent valve electrical connector.
  8.  
  9. Install the fuel tank straps.
  10.  
  11. Install the fuel tank strap bolts and tighten to 24 ft. lbs. (32 Nm).
  12.  
  13. Remove the caps from the fuel and EVAP pipes.
  14.  
  15. Connect the fuel feed pipe and EVAP pipe as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  16.  
  17. Connect the fuel hose to the fuel tank and tighten the clamp to 22 inch lbs. (2.5 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Refill the fuel tank.
  22.  
  23. Install the fuel fill cap.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Inspect for leaks as follows:
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  28.  
  29. Install the fuel tank shield to the frame, if equipped, then install the retaining bolts and nut and tighten to 24 ft. lbs. (32 Nm).
  30.  
  31. Install the frame brace to the frame using the mounting bolts and tighten them to 37 ft. lbs. (50 Nm).
  32.  
  33. Lower the vehicle.
  34.  

Standard Wheelbase Models



  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle securely on jackstands.
  6.  
  7. Remove the 2 mounting bolts from the frame brace and remove the frame brace from the frame.
  8.  
  9. Remove the fuel tank shield to the frame retaining bolts and nut, then remove the fuel tank shield from the frame.
  10.  
  11. Drain the fuel tank as follows:
    1. Loosen the fuel fill hose clamp.
    2.  
    3. Disconnect the fuel fill hose from the fuel tank.
    4.  
    5. Use a hand or air operated pump device in order to drain as much fuel from the fuel tank as possible.

      Click image to see an enlarged view

      Fig. Disconnect the EVAP canister fresh air pipe, EVAP canister solenoid pipe and EVAP purge pipe from the fuel tank-Envoy, Rainier and TrailBlazer

    6.  

  12.  
  13. Disconnect the evaporative emission (EVAP) canister fresh air pipe.
  14.  
  15. Disconnect the EVAP canister solenoid pipe.
  16.  
  17. Disconnect the EVAP purge pipe.
  18.  
  19. Disconnect the fuel filler pipe recirculation hose from the fuel tank.
  20.  
  21. Loosen the clamp securing the fuel fill pipe to the fuel tank.
  22.  
  23. Disconnect the fuel fill pipe from the fuel tank.

    Click image to see an enlarged view

    Fig. Disconnect the EVAP pipe (1) and the fuel feed pipe (2) from the fuel tank-Envoy, Rainier and TrailBlazer

  24.  
  25. Disconnect the fuel feed pipe (2) and EVAP pipe (1) from the fuel tank.
  26.  
  27. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
  28.  
  29. Support the fuel tank.

    Click image to see an enlarged view

    Fig. Remove the fuel tank straps and carefully lower the fuel tank -Envoy, Rainier and TrailBlazer

  30.  
  31. Remove the fuel tank strap attaching bolts.
  32.  
  33. Remove the fuel tank straps.
  34.  
  35. Carefully lower the fuel tank.
  36.  
  37. Disconnect the EVAP vent valve electrical connector.
  38.  
  39. Disconnect the fuel tank pressure sensor electrical connector.
  40.  
  41. Disconnect the fuel sender electrical connector.
  42.  
  43. Remove the fuel tank.
  44.  
  45. Place the fuel tank in a suitable work area.
  46.  

To install:

  1. Support the fuel tank.
  2.  
  3. Connect the fuel sender electrical connector.
  4.  
  5. Connect the EVAP vent valve electrical connector.
  6.  
  7. Connect the fuel pressure sensor electrical connector.
  8.  
  9. Install the fuel tank straps.
  10.  
  11. Install the fuel tank strap attaching bolts and tighten to 24 ft. lbs. (32 Nm).
  12.  
  13. Remove the caps from the fuel and EVAP pipes.
  14.  
  15. Connect the fuel feed pipe (1) and the EVAP pipe (2) as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  16.  
  17. Connect the fuel fill pipe to the fuel tank and tighten the fuel fill hose clamp to 22 inch lbs. (2.5 Nm).
  18.  
  19. Connect the fuel filler pipe recirculation hose to the fuel tank as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  20.  
  21. Connect the EVAP purge pipe as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  22.  
  23. Connect the EVAP canister solenoid pipe as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  24.  
  25. Connect the EVAP canister fresh air pipe as follows:
    1. Apply a few drops of clean engine oil to the male connection end.
    2.  
    3. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
    4.  
    5. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.
    6.  

  26.  
  27. Lower the vehicle.
  28.  
  29. Refill the fuel tank.
  30.  
  31. Install the fuel filler cap.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Raise the vehicle.
  36.  
  37. Inspect for leaks as follows:
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition, with the engine OFF.
    6.  
    7. Inspect for fuel leaks.
    8.  

  38.  
  39. Install the fuel tank shield, if equipped, to the frame and tighten the retaining bolts and nut to 24 ft. lbs. (32 Nm).
  40.  
  41. Install the frame brace to the frame using the 2 mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  42.  
  43. Lower the vehicle.
  44.  

 
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