GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Astro - 4WD 🢒 Engine 🢒 Engine Controls - 4.3L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Loosen the filler neck hose clamp at the fuel tank.
  5. Disconnect the fuel tank filler neck from the fuel tank. Refer to Filler Tube Replacement .

    6. Object Number: 758077 Size: SH
  6. Disconnect the fuel tank pipes (1) from the fuel feed (2) and fuel return (5) pipes.

    7. Object Number: 712757 Size: SH
  7. Disconnect the EVAP purge pipe (4).

    8. Object Number: 710858 Size: SH
  8. Disconnect the fuel sender electrical connector (2).
  9. Support the fuel tank.

    10. Object Number: 710855 Size: SH
  10. Remove the fuel tank strap bolts (3) and the fuel tank straps.
  11. Remove the fuel tank.

    12. Object Number: 758174 Size: SH
  12. Remove the fuel sender assembly (4). Refer to Fuel Sender Assembly Replacement .
  13. Remove the EVAP canister (1). Refer to Evaporative Emission Canister Replacement .

Installation Procedure
  1. Install the fuel sender assembly (4). Refer to Fuel Sender Assembly Replacement .

    2. Object Number: 758174 Size: SH
  2. Install the EVAP canister (1). Refer to Evaporative Emission Canister Replacement .

    3. Object Number: 710855 Size: SH

    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.

    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.

  3. Install the fuel tank and the fuel tank straps.

    4. 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.

  4. Install the fuel tank strap bolts (3).

    5. Tighten
    Tighten the strap bolts to 35 N·m (26 lb ft).


    Object Number: 710858 Size: SH
  5. Connect the fuel sender electrical connector (2).

    6. Object Number: 712757 Size: SH
  6. Connect the EVAP purge pipe (4).

    7. Object Number: 758077 Size: SH
  7. Connect the fuel tank pipes (1) to the fuel feed (2) and fuel return (5) pipes.
  8. Connect the fuel tank filler neck to the fuel tank. Refer to Filler Tube Replacement .
  9. Lower the vehicle.
  10. Refill the fuel tank.
  11. Install the fuel tank filler cap.
  12. Connect the negative battery cable.

    13. 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.

  13. Inspect for leaks using the following procedure.
    14. 13.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition, with the engine off.
    13.4. Inspect for fuel leaks.
  14. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.