GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Chevy P32 RV/Van Chassis 🢒 Engine 🢒 Engine Controls - 7.4L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  2. Raise the vehicle.

    3. Object Number: 240502 Size: SH
  3. Remove the fuel tank rear shield, if equipped.

    4. Object Number: 240436 Size: SH
  4. Remove the fuel tank side shield, if equipped.

    5. Object Number: 240521 Size: SH
  5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    6. Object Number: 240521 Size: SH
  6. With the aid of an assistant lower the fuel tank.
  7. Disconnect the fuel feed and vapor hoses.
  8. Disconnect the electrical connections at the sender.

    9. Object Number: 65287 Size: SH
  9. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Witht the aid of an assistant, raise the tank enough to reconnect the fuel feed and vapor hoses and the electrical connections at the sender.

    3. Object Number: 240521 Size: SH
  3. Raise the tank fully.

    4. Object Number: 240521 Size: SH
  4. Support the fuel tank and install the tank straps and the insulator strips.

    5. Important: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

    Notice: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.

  5. Install the fuel tank brackets with insulator strips in place.

    6. Tighten
    Tighten the strap nuts to 45 N·m (33 lb ft).

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


    Object Number: 240502 Size: SH
  6. Install the rear fuel tank shield.

    7. Object Number: 240436 Size: SH
  7. Install the fuel tank side shield.
  8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  9. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
  10. Check for fuel leaks.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.