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For 1990-2009 cars only

Fuel Tank Replacement Suburban

Removal Procedure

Tools Required

J 39765 Fuel Sender Locknut Wrench.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

  4. Object Number: 18322  Size: SH
  5. Remove the fuel tank off-road shield, if equipped.

  6. Object Number: 18442  Size: SH
  7. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  8. Object Number: 18311  Size: SH
  9. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

  10. Object Number: 18313  Size: SH
  11. Lower the fuel tank shield.

  12. Object Number: 18321  Size: SH
  13. Lower the fuel tank. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.

  14. Object Number: 65287  Size: SH
  15. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


    Object Number: 65287  Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.

  3. Object Number: 18321  Size: SH
  4. Completely raise the fuel tank.
  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.

  6. Install the fuel tank straps and fastening hardware.

  7. Object Number: 18442  Size: SH
  8. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  9. Object Number: 18311  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.

    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.

  10. Install the fuel tank straps with insulator strips in place.
  11. Install the fuel tank strap bolts.

    Tighten
    Tighten the fuel tank strap bolts to 13N·m (115 lb in).


    Object Number: 18322  Size: SH
  12. Install the fuel tank off-road shield, if equipped.
  13. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  14. 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.
  15. Check for leaks.
  16. 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.

Fuel Tank Replacement Tahoe/Yukon

Removal Procedure

Tools Required

J 39765 fuel sender locknut wrench.

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

   • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
   • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Relieve the fuel system pressure. Refer to Fuel Tank Draining Procedure
  4. Raise the vehicle.

  5. Object Number: 18442  Size: SH
  6. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  7. Object Number: 18329  Size: SH
  8. Support the fuel tank and loosen the tank straps and remove insulator strips, if equipped.

  9. Object Number: 18321  Size: SH
  10. With the aid of an assistant lower and support the fuel tank and shield.
  11. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Disconnect the fuel feed and vapor hoses.
  12. Disconnect the electrical connections at the sender.
  13. Remove the fuel tank straps.
  14. Remove the fuel tank and place in a suitable work area.

  15. Object Number: 65287  Size: SH
  16. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


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

  3. Object Number: 18321  Size: SH
  4. Raise the tank fully.
  5. Install the fuel tank straps and fastening hardware.
  6. 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.


    Object Number: 18442  Size: SH
  7. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  8. Object Number: 18329  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.

    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.

  9. Install the fuel tank straps with insulator strips in place.
  10. Tighten
    Tighten the strap nuts to 13 N·m (115 lb in).


    Object Number: 18318  Size: SH
  11. Install the fuel tank off-road shield, if equipped.
  12. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  13. 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.
  14. Check for fuel leaks.
  15. 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.

Fuel Tank Replacement Extended Cab - Side Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut wrench.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

  4. Object Number: 18442  Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  6. Object Number: 18413  Size: SH
  7. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

  8. Object Number: 18414  Size: SH
  9. Lower the fuel tank shield.

  10. Object Number: 18415  Size: SH
  11. Lower the fuel tank.

  12. Object Number: 19204  Size: SH
  13. Disconnect the fuel feed (1) and vapor (2) hoses.
  14. Disconnect the electrical connections at the sender.

  15. Object Number: 65287  Size: SH
  16. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


    Object Number: 65287  Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

  2. Object Number: 19204  Size: SH
  3. Raise the tank slightly and reconnect the fuel feed (1) vapor (2) hoses and the electrical connector at the sender.

  4. Object Number: 18415  Size: SH
  5. Raise the fuel tank fully.

  6. Object Number: 18414  Size: SH
  7. Install the fuel tank shield.
  8. Install the fuel tank straps and fastening hardware.
  9. 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.


    Object Number: 18442  Size: SH
  10. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  11. Object Number: 18413  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.

    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.

  12. Install the fuel tank brackets with insulator strips in place.
  13. Tighten
    Tighten the fuel tank strap fasteners to 13 N·m (115 lb in).

  14. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  15. 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.
  16. Check for fuel leaks.
  17. 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.

Fuel Tank Replacement Pick-up - Side Tank

Removal Procedure

Tools Required

J 39765 Fuel Sender Locknut Wrench.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

  4. Object Number: 18442  Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  6. Object Number: 18407  Size: SH
  7. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

  8. Object Number: 18406  Size: SH
  9. Remove the frame mounted bracket.

  10. Object Number: 18408  Size: SH
  11. Lower the fuel tank shield.

  12. Object Number: 18409  Size: SH
  13. Lower the fuel tank.

  14. Object Number: 19204  Size: SH
  15. Disconnect the fuel feed (1) and vapor (2) hoses. Disconnect the electrical connector at the sender.

  16. Object Number: 65287  Size: SH
  17. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


    Object Number: 65287  Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

  2. Object Number: 19204  Size: SH
  3. Raise the tank slightly and reconnect the fuel feed (1), vapor (2) hoses and the electrical connector at the sender.

  4. Object Number: 18409  Size: SH
  5. Raise the fuel tank fully.

  6. Object Number: 18408  Size: SH
  7. Install the fuel tank shield.
  8. Install the fuel tank straps and fastening hardware.
  9. 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.


    Object Number: 18442  Size: SH
  10. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  11. Object Number: 18406  Size: SH
  12. Install the frame mounted bracket.
  13. Tighten
    Tighten the fasteners to 33 N·m(45 lb ft).


    Object Number: 18407  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.

    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.

  14. Install the fuel tank brackets with insulator strips in place.
  15. Tighten
    Tighten the strap nuts to 13 N·m (115 lb in).

  16. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  17. 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.
  18. Check for fuel leaks.
  19. 11.1. Turn ON the ignition switch for 2 seconds.
    11.2. Turn OFF the ignition switch for 10 seconds.
    11.3. Again, turn the ignition switch to the ON position.
    11.4. Check for fuel leaks.

Fuel Tank Replacement Cab and Chassis - Side Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut wrench.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

  4. Object Number: 18440  Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  6. Object Number: 18418  Size: SH
  7. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

  8. Object Number: 18419  Size: SH
  9. Lower the fuel tank shield.

  10. Object Number: 18420  Size: SH
  11. Lower the fuel tank.

  12. Object Number: 19204  Size: SH
  13. Disconnect the fuel feed (1) and vapor (2) hoses.
  14. Disconnect the electrical connections at the sender.

  15. Object Number: 65287  Size: SH
  16. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


    Object Number: 65287  Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

  2. Object Number: 19204  Size: SH
  3. Raise the tank slightly and reconnect the fuel feed (1) vapor (2) hoses and the electrical connector at the sender.

  4. Object Number: 18420  Size: SH
  5. Raise the fuel tank fully.

  6. Object Number: 18419  Size: SH
  7. Install the fuel tank shield.
  8. Install the fuel tank straps and fastening hardware with insulator strips in place.
  9. 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.


    Object Number: 18440  Size: SH
  10. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  11. Object Number: 18418  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.

    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.

    Tighten
    Tighten the strap nuts to 13 N·m (115 lb in).

  12. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  13. 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.
  14. Check for fuel leaks.
  15. 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.

Fuel Tank Replacement Cab and Chassis - Rear Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut wrench.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

  4. Object Number: 421914  Size: SH
  5. Remove the fuel tank off-road shield, if equipped.

  6. Object Number: 18440  Size: SH
  7. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

  8. Object Number: 421915  Size: SH
  9. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

  10. Object Number: 18425  Size: SH
  11. Lower the fuel tank.
  12. Disconnect the fuel feed and vapor hoses.
  13. Disconnect the electrical connections at the sender.

  14. Object Number: 421912  Size: SH
  15. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure


    Object Number: 421912  Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.

  3. Object Number: 18425  Size: SH
  4. Raise the fuel tank fully.
  5. Install the fuel tank straps and fastening hardware.
  6. 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.


    Object Number: 18440  Size: SH
  7. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

  8. Object Number: 421915  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.

    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.

  9. Install the fuel tank brackets with insulator strips in place.
  10. Tighten
    Tighten the strap bolts to 35 N·m (47 lb ft).


    Object Number: 421914  Size: SH
  11. Install the fuel tank off-road shield, if equipped.
  12. 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.

    Tighten
    Tighten the fuel tank shield fastening hardware to 74 N·m(102 lb ft).

  13. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  14. 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.
  15. Check for fuel leaks.
  16. 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.

Fuel Tank Replacement 4 Door Utility

Removal Procedure

  1. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure .
  2. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)

  3. Object Number: 18431  Size: SH
  4. Remove the filler hose and vent hose from the fuel tank.

  5. Object Number: 18436  Size: SH
  6. Support the fuel tank and remove the fuel tank straps.

  7. Object Number: 18437  Size: SH
  8. Lower the fuel tank shield and the fuel tank.

  9. Object Number: 381574  Size: SH
  10. Disconnect the fuel feed (1) and vapor (2) hoses.
  11. Disconnect the electrical connector at the sender.

  12. Object Number: 18438  Size: SH
  13. Remove the fuel tank.

  14. Object Number: 65287  Size: SH
  15. Remove the fuel sender and the seal ring. Discard the old seal ring.

Installation Procedure


    Object Number: 65287  Size: SH
  1. Install the new seal ring and reinstall the sender.
  2. Raise the tank and reconnect the electrical connector at the sender.

  3. Object Number: 18447  Size: SH
  4. Reconnect the fuel feed and vapor hoses.

  5. Object Number: 18437  Size: SH
  6. Raise the tank fully and reinstall the tank shield.

  7. Object Number: 18436  Size: SH

    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.

  8. Reinstall the tank straps.
  9. Tighten
    Tighten the bolts to 35 N·m (47 lb ft).


    Object Number: 18432  Size: SH
  10. Reinstall the filler hose and the vent hose to the tank.
  11. Replenish the fuel. Reinstall the fuel tank filler cap.
  12. Reconnect the negative battery cable.
  13. Check for fuel leaks.
  14. 9.1. Turn ON the ignition switch for 2 seconds.
    9.2. Turn OFF the ignition switch for 10 seconds.
    9.3. Again, turn the ignition switch to the ON position.
    9.4. Check for fuel leaks.