GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Kodiak C-Series (Conventional) C6/C7/C8 🢒 Engine 🢒 Engine Controls - 7.8L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  2. If equipped with air tank , loosen the air tank clamp nuts and position the air tank to gain access to the fuel tank supports.
  3. Support the fuel tank .

    4. Object Number: 816451 Size: SH
  4. Remove the fuel tank support nuts .

    5. Object Number: 816417 Size: SH

    Important: The fuel lines are designed to uncoil and flex to provide added ease of removal. It may be necessary to remove the tape around the fuel line coil to gain more access.

  5. Lower the fuel tank enough to disconnect the fuel coil lines and electrical connector.
  6. Disconnect the fuel and EVAP lines. Refer to CELL LINK 134181 and CELl LINK 134182.
  7. Disconnect the fuel sender assembly electrical connector.
  8. Remove the fuel tank with the fuel tank supports from the frame rail.

    9. Object Number: 1253407 Size: SH
  9. Remove the fuel line coil from the fuel sending unit. Refer to CELL LINK 134181.
  10. Remove the fuel sender assembly if replacing or servicing the tank. Refer to Fuel Sender Assembly Replacement .
  11. Remove the fuel tank steps. Refer to Step Replacement in Body Front End.
  12. Remove the nuts, washers, and both fuel tank straps and supports from the fuel tank.
  13. Remove the nut and the fuel sender assembly ground lead from the fuel tank. Note the position of ground lead for installation.
  14. Remove the fuel cap chain retainer and fuel cap if fuel tank is being replaced.
  15. Purge the tank if the tank is being serviced. Refer to Fuel System Cleaning .

Installation Procedure

    Object Number: 724691 Size: SH
  1. Install the fuel sender assembly if replacing or servicing the tank.
  2. Install the fuel line coil (1, 3) to the fuel sending unit (2). Refer to CELL LINK 134181.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the fuel tank ground lead.

    4. Tighten
    Tighten the nut to 9 N·m (7 lb ft).

  4. Install fuel tank chain to the fuel tank with retainer, if removed.
  5. Install the fuel tank onto the fuel tank supports with the strap to the fuel tank supports.
  6. Install the fuel tank strap nuts and the washers .

    7. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).

  7. Slide the fuel tank into position and support the fuel tank.
  8. Reconnect the fuel sender assembly electrical connector.

    9. Object Number: 1253407 Size: SH
  9. Install the fuel feed, fuel return , and EVAP lines to the fuel sender assembly . Refer to CELL LINK 134181 and to CELL LINK 134182.
  10. If fuel line tape was removed, tape fuel line coil.

    11. Object Number: 816450 Size: SH
  11. Install the fuel tank supports to the frame with 2 anchor plates and 6 nuts.

    12. Tighten
    Tighten nuts to 175 N·m (129 lb ft).

  12. Install the fuel tank steps. Refer to Step Replacement in Body Front End.
  13. Refill the fuel tank.
  14. Inspect for leaks.