Chevrolet Trax: Fuel tank draining

Special Tool

CH 45004 Fuel Tank Drain Hose

WARNING: Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.

WARNING: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.

1. Remove the fuel fill cap.

Fig. 14: Fuel Sender O-Ring Gasket

2. Remove the fuel tank sender. Refer to Fuel Sender Assembly Replacement (AWD).
3. With the fuel tank sender (1) and seal (2) removed, insert the CH 45004 hose into the fuel tank until the bottom is reached.
4. Using an appropriate pump or syphon, drain as much fuel from the tank as possible.

FUEL TANK REPLACEMENT

Removal Procedure

WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. WARNING: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
2. Drain the fuel tank. Refer to Fuel Tank Draining.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the exhaust. Refer to Exhaust Muffler Replacement (LUV) .
5. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
6. Remove the right rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .

Fig. 15: Fuel Tank Fuel Pump Module Wiring Harness

7. Disconnect the fuel tank fuel pump module wiring harness (1) and unclip the fuel tank module wiring harness from the chassis.
8. Disconnect the fuel tank filler pipe. Refer to Fuel Tank Filler Pipe Replacement.
9. Disconnect the fuel feed pipe. Fuel Feed Pipe Replacement (At Tank AWD)
10. Disconnect the EVAP system hoses. Refer to Evaporative Emission System Hose/Pipe Replacement (Fuel Pump Module to Canister AWD)Evaporative Emission System Hose/Pipe Replacement (Canister to Pipe AWD).
11. Position a suitable hydraulic lift below the fuel tank.

Fig. 16: Fuel Tank Straps And Fasteners

12. Remove both fuel tank strap fasteners (1).
13. Remove both fuel tank straps from the fuel tank (2).

WARNING: To help avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported only by a jack.

CAUTION: When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the lift pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle damage or unsatisfactory vehicle performance may result.

14. With the aid of an assistant, lower the hydraulic lift to remove the fuel tank from the vehicle.
15. Remove the fuel tank from the hydraulic lift.
16. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (AWD).
17. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement (AWD).
18. Remove the evaporative emission canister. Refer to Evaporative Emission Canister Replacement (AWD).

Installation Procedure

1. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement (AWD).
2. Transfer the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement (AWD).
3. Transfer the evaporative emission canister. Refer to Evaporative Emission Canister Replacement (AWD).
4. Install the fuel tank to the hydraulic lift.

Fig. 17: Fuel Tank Straps And Fasteners

5. With the aid of an assistant, position the fuel tank to the vehicle.

CAUTION: Refer to Fastener Caution .

6. Install both fuel tank straps to the fuel tank (2) and tighten the fasteners to 22 (16 lb ft).
7. Remove the hydraulic lift from the fuel tank.
8. Connect the EVAP system hoses. Refer to Evaporative Emission System Hose/Pipe Replacement (Fuel Pump Module to Canister AWD)Evaporative Emission System Hose/Pipe Replacement (Canister to Pipe AWD).
9. Connect the fuel feed pipe. Refer to Fuel Feed Pipe Replacement (At Tank AWD).
10. Connect the fuel tank filler pipe. Refer to Fuel Tank Filler Pipe Replacement.

Fig. 18: Fuel Tank Fuel Pump Module Wiring Harness

11. Connect the fuel tank fuel pump module wiring harness (1) and clip the fuel tank module wiring harness to the chassis.
12. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
13. Install the exhaust. Refer to Exhaust Muffler Replacement (LUV)
14. Install the right rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement .
15. Lower the vehicle.

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