Captiva

Fuel Tank Replacement - AWD

Warning: Do not allow smoking or the use of naked flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Warning: Fuel supply lines will remain pressurised for a long period of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to Fuel Tank Draining .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the exhaust system. Refer to Exhaust Muffler Replacement : NB5 .
5. Remove the propeller shaft. Refer to Propeller Shaft Replacement .




Warning: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

Caution: Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes to avoid contamination of the fuel system.

6. Remove the evaporative emission canister . Refer to Evaporative Emission Canister Replacement .
7. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis fuel feed line (2), if necessary. Refer to Plastic Collar Quick Connect Fitting Service .
8. Disconnect the fresh air tube quick disconnect (3).



9. Disconnect the fill pipe vent line quick connect fitting (4) from the fuel tank fresh air line (3). Refer to Plastic Collar Quick Connect Fitting Service .
10. Disconnect the fuel tank vapour line quick connect fitting (2) from the fill pipe recirculation line (5). Refer to Plastic Collar Quick Connect Fitting Service .
11. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
12. Remove the fuel fill pipe (6) hose from the fuel tank.
13. Remove the rear parking brake cable to frame rail bolts. Unclip parking brake cables from fuel tank straps, and reposition parking brake cables to provide clearance for fuel tank removal.



14. Using a suitable adjustable jack, support the fuel tank.

Caution: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

15. Remove the fuel tank strap nuts (2) and straps (1).

Note: It is not necessary to remove the rear drive module (RDM) in order to remove the fuel tank.

16. Using the adjustable jack, slowly lower and reposition the fuel tank (3) in order to remove the tank from the vehicle. Using the adjustable jack, slowly lower the front of the fuel tank. Pull the fuel tank forward to clear the rear drive module (RDM) and remove the fuel tank assembly with shield from the vehicle.
17. If replacing the fuel tank perform the following steps, otherwise proceed to the Installation Procedure.

1. Disengage the fresh air line (1) from the fuel tank clips and remove the fresh air line.



2. Disconnect the fuel feed line quick connect fitting (1) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
3. Open the retaining clip (3) on the fuel tank and remove the fuel feed line (2).



4. Disconnect the vapour line quick connect fitting (1) from the fuel tank vent valve. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the vapour line quick connect fittings (2) from the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
6. Remove the vapour line (5) from the retaining clip (4) and the retaining features (3) moulded into the fuel tank.



7. Disconnect the fuel tank wiring harness (1) electrical connectors from the following:

•	Primary fuel tank fuel pump module

•	Fuel tank pressure sensor

•	Secondary fuel tank fuel pump module

8. Remove the fuel tank wiring harness from the retaining clips (2 and 4) and the retaining features (3) moulded into the fuel tank.



9. Remove the fuel tank shield retainers (1) and shield (2).
10. Remove the fuel tank fuel pump modules. Refer to Fuel Tank Fuel Pump Module Replacement and Fuel Tank Fuel Pump Module Replacement - Secondary .

1. Install the fuel tank fuel pump modules. Refer to Fuel Tank Fuel Pump Module Replacement and Fuel Tank Fuel Pump Module Replacement - Secondary .
2. Install the fuel tank shield (2) and retainers (1).



3. Connect the fuel tank wiring harness (1) electrical connectors to the following:

•	Secondary fuel tank fuel pump module

•	Fuel tank pressure sensor

•	Primary fuel tank fuel pump module

4. Install the fuel tank wiring harness to the retaining clips (2 and 4) and the retaining features (3) moulded into the fuel tank.



5. Lay the vapour line (5) into position and connect the vapour line quick connect fittings (2) to the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
6. Connect the vapour line quick connect fitting (1) to the fuel tank vent valve. Refer to Plastic Collar Quick Connect Fitting Service .
7. Install the vapour line to the retaining clip (4) and the retaining features (3) moulded into the fuel tank.



8. Lay the fuel feed line (2) into position and connect the fuel feed line quick connect fitting (1) to the fuel tank fuel pump module. Refer to Plastic Collar Quick Connect Fitting Service .
9. Close the retaining clip (3) on the fuel tank.



10. Position the fresh air line (1) to the fuel tank clips and install the fresh air line.

1. Using the adjustable jack, slowly raise and reposition the fuel tank (3) in order to install the tank to the vehicle.

Caution: Refer to Fastener Caution in the Preface section.

Caution: Do not bend the fuel tank straps. Bending the fuel tank straps may cause damage to the straps.

2. Install the fuel tank straps (1) and nuts (2).

Tighten
Tighten the nuts to 20 N·m (15 lb ft).

3. Remove the adjustable jack from under the fuel tank.




Note: Ensure that the notch in the fuel fill pipe hose aligns with the locating tab on the fuel tank.

4. Clip the parking brake cables to the fuel tank straps. Install the rear parking brake cable to frame rail bolts.
5. Install the evaporative emission canister . Refer to Evaporative Emission Canister Replacement .
6. Install the fuel fill pipe (6) hose to the fuel tank.
7. Tighten the fuel fill pipe hose clamp (1) at the fuel tank.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

8. Connect the fuel tank vapour line quick connect fitting (2) to the fill pipe recirculation line (5). Refer to Plastic Collar Quick Connect Fitting Service .
9. Connect the fill pipe vent line quick connect fitting (4) to the fuel tank fresh air line (3). Refer to Plastic Collar Quick Connect Fitting Service .
10. Install the propeller shaft. Refer to Propeller Shaft Replacement .
11. Install the exhaust system. Refer to Exhaust Muffler Replacement : NB5 .
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
13. Perform the following procedure in order to inspect for leaks:

•	Turn the ignition ON, with the engine OFF, for 2 seconds.

•	Turn the ignition OFF for 10 seconds.

•	Turn the ignition ON, with the engine OFF.

•	Inspect for fuel leaks.