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HOMESERVICE MANUALSCHEVROLET2009TAHOE BASE, 4.8 CREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 276 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - HYBRID (LZ1) - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2009 Chevrolet Tahoe Base, 4.8 C

Installation Procedure

2009 Chevrolet Tahoe Base, 4.8 CSECTION Installation Procedure
WARNING: This page is about a different car, the 2010 GMC Yukon, 2010 Chevrolet Tahoe, and 2010 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Quick Connect Fittings At Module Cover
    GM1254425Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced perform the following steps, otherwise proceed to step 18.
  2. Install the NEW fuel tank module seal onto the fuel tank.
  3. Pull the vent lines in the fuel tank up as far as possible for ease of installation.
  4. Position the fuel tank module part way into the fuel tank.
  5. Connect the quick connect fittings (1) to the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Install the fuel tank module into the fuel tank.
  7. Place the lock ring into position.
    8. NOTE: Always replace the fuel module seal when installing the fuel module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  8. Rotate the lock ring counterclockwise using the J 45722  .
    9. Fig 2: View Of Fuel Tank EVAP Lines
    GM1704507Courtesy of GENERAL MOTORS CORP.
  9. Install the EVAP lines to the fuel tank.
    10. Fig 3: View Of Fuel Tank Clips
    GM1704505Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP line quick connect fittings at the fuel tank module and fuel tank vent valve. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Install the EVAP lines to the fuel tank clips (1, 3, 4, and 5) and close the clips.
  12. Install the EVAP line to the fuel tank clips (2 and 6).
    13. Fig 4: View Of Fuel Tank Shield & Retainers
    GM1704741Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank shields (1 and 4) and retainers (2 and 3).
    14. Fig 5: View Of Fuel Feed Line
    GM1704506Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel feed line to the fuel tank.
    15. Fig 6: View Of EVAP Line Clip & Retainer
    GM1704504Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel feed line quick connect fitting at the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  16. Install the fuel feed line to the clip (1) and close the clip.
  17. Install the fuel feed line to the retaining feature (2) in the fuel tank.
    18. Fig 7: View Of Chassis Wiring Harness Electrical Connectors
    GM1704493Courtesy of GENERAL MOTORS CORP.
  18. Place the fuel tank onto a suitable jack.
  19. With the aid of an assistant, partially raise the fuel tank until the electrical connections can be made.
  20. Connect the chassis wiring harness electrical connectors (1) to the fuel tank module and fuel pressure sensor.
  21. Engage the chassis harness electrical connector CPA retainer at the module electrical connector.
    22. Fig 8: View Of Fuel Tank & Straps (Single Tank)
    GM1224293Courtesy of GENERAL MOTORS CORP.
  22. Completely raise the fuel tank.
  23. Install the fuel tank straps.
    24. CAUTION: Refer to Fastener Caution .
  24. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

  25. Remove the adjustable jack from the fuel tank.
    26. Fig 9: View Of Fuel Tank EVAP Lines & Canister
    GM1704492Courtesy of GENERAL MOTORS CORP.
  26. Remove the caps from the EVAP lines.
  27. Connect the fuel tank EVAP lines (1) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    28. Fig 10: View Of EVAP Lines, Fuel Feed Lines & Fittings
    GM1704490Courtesy of GENERAL MOTORS CORP.
  28. Remove the caps from the fuel and EVAP lines.
  29. Connect the chassis EVAP line quick connect fitting (4) to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service .
  30. Connect the fuel tank fuel feed line quick connect fitting (5) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    31. Fig 11: View Of Fuel Vent Hose Clamp & Fuel Filler Hose Clamp
    GM1964118Courtesy of GENERAL MOTORS CORP.
  31. Install the fuel fill pipe vent hose to the fuel tank vent valve.
  32. Tighten the fuel fill pipe vent hose clamp (2) at the fuel tank vent valve.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  33. Install the fuel fill hose to the fuel tank. Ensure that the notch in the hose is aligned with the notch on the fuel tank.
  34. Tighten the fuel fill hose clamp (1).

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  35. Lower the vehicle.
  36. Refill the fuel tank.
  37. Install the fuel fill cap.
  38. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  39. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
  40. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.