GM Service Manual Online
For 1990-2009 cars only

Fuel Tank Replacement Pickup

Removal Procedure


    Object Number: 816707  Size: SH
  1. Drain the fuel tank. Refer to Fuel Tank Draining .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
  4. Loosen the clamp at the fuel inlet neck.
  5. Remove the fuel fill hose from the inlet neck.
  6. Remove the fuel system cooler. Refer to Fuel Cooler Replacement .

  7. Object Number: 626413  Size: SH
  8. Remove the fuel tank shield bolts, if equipped.
  9. Remove the fuel tank shield, if equipped.

  10. Object Number: 877717  Size: SH
  11. Disconnect the fuel feed and return pipes from the fuel tank pipes. Refer to Metal Collar Quick Connect Fitting Service .
  12. Cap the fuel pipes in order to prevent possible fuel system contamination.
  13. Place a suitable adjustable jack under the fuel tank.
  14. Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.


    Object Number: 300138  Size: SH
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.
  17. Remove the fuel tank.
  18. Lower the fuel tank until the electrical connector is accessible.
  19. Disconnect the sending unit electrical connector.
  20. With the aid of an assistant, place the fuel tank in a suitable work area.
  21. If necessary, loosen the fuel inlet hose clamp at the tank.
  22. If necessary, remove the fuel inlet hose from the tank.

  23. Object Number: 738174  Size: SH
  24. Disconnect and remove the fuel feed and return pipes from the sending unit (1) and retaining clips (3). Refer to Plastic Collar Quick Connect Fitting Service .
  25. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

Installation Procedure


    Object Number: 738174  Size: SH
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Install and connect the fuel feed and return pipes to the sending unit (1) and retaining clips (3). Refer to Plastic Collar Quick Connect Fitting Service .

  3. Object Number: 300138  Size: SH
  4. If necessary, install the fuel inlet hose to the tank.
  5. 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.

  6. If necessary, tighten the fuel inlet hose clamp at the tank.
  7. Tighten
    Tighten the clamp to 2.5 N·m (22 lb in).

  8. With the aid of an assistant, place the fuel tank on the jack.
  9. Raise the fuel tank until the electrical connector is accessible.
  10. Connect the sending unit electrical connector.
  11. Install the fuel tank.
  12. Install the fuel tank straps.
  13. Install the fuel tank strap bolts.
  14. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).

  15. Remove the jack from under the fuel tank.

  16. Object Number: 877717  Size: SH
  17. Remove the caps from the fuel pipes.
  18. Connect the fuel feed and return pipes from the fuel tank pipes. Refer to Metal Collar Quick Connect Fitting Service .

  19. Object Number: 626413  Size: SH
  20. Install the fuel tank shield, if equipped.
  21. Install the fuel tank shield bolts, if equipped.
  22. Tighten
    Tighten the bolts to 18 N·m (13 lb ft).

  23. Install the fuel system cooler. Refer to Fuel Cooler Replacement .

  24. Object Number: 816707  Size: SH
  25. Install the fuel fill hose to the inlet neck.
  26. Tighten the clamp at the fuel inlet neck.
  27. Tighten
    Tighten the clamp to 2.5 N·m (22 lb in).

  28. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  29. Lower the vehicle.
  30. Fill the fuel tank.
  31. Install the fuel fill cap.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  33. Prime the fuel system.
  34. Start the engine and test for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Front

Removal Procedure


    Object Number: 877728  Size: SH
  1. Disconnect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .

  2. Object Number: 877738  Size: SH
  3. Loosen the fuel fill and vent hose clamps at the fuel tank.
  4. Remove the fuel fill pipe and vent hose from the tank.
  5. Drain the fuel tank. Refer to Fuel Tank Draining .
  6. Disconnect the sending unit electrical connector.

  7. Object Number: 877707  Size: SH
  8. Disconnect the fuel feed/return pipes from the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
  9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  10. Object Number: 877744  Size: SH
  11. Remove the fuel tank shield bolts.
  12. Remove the fuel tank shield.
  13. Place a suitable adjustable jack under the fuel tank.
  14. Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.


    Object Number: 667731  Size: SH
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps (1).
  17. Lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. Cap the fuel pipes on the vehicle in order to prevent possible fuel system contamination.
  20. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

Installation Procedure


    Object Number: 667731  Size: SH
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps (1).
  6. 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.

  7. Install the fuel tank strap bolts.
  8. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).

  9. Remove the jack from under the fuel tank.

  10. Object Number: 877744  Size: SH
  11. Install the fuel tank shield.
  12. Install the fuel tank shield bolts.
  13. Tighten
    Tighten the bolts to 18 N·m (13 lb ft).

  14. Lower the vehicle.

  15. Object Number: 877707  Size: SH
  16. Connect the fuel feed/return pipes at the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
  17. Connect the sending unit electrical connector.

  18. Object Number: 877738  Size: SH
  19. Install the fuel fill pipe and vent hose to the tank.
  20. Tighten the fuel fill and vent hose clamps at the fuel tank.
  21. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).


    Object Number: 877728  Size: SH
  22. Connect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .
  23. Fill the fuel tank.
  24. Install the fuel fill cap.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  26. Prime the fuel system.
  27. Start the engine and test for fuel leaks.

Fuel Tank Replacement Cab/Chassis - Rear

Removal Procedure


    Object Number: 877741  Size: SH
  1. Loosen the fuel fill and vent hose clamps at the tank.
  2. Remove the fuel fill and vent hose from the tank.
  3. Drain the fuel tank. Refer to Fuel Tank Draining .

  4. Object Number: 877754  Size: SH
  5. Disconnect the sending unit electrical connector (2).

  6. Object Number: 881567  Size: SH
  7. Disconnect the fuel feed/return pipes from the sending unit. Refer to Metal Collar Quick Connect Fitting Service .
  8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  9. Object Number: 877746  Size: SH
  10. Remove the fuel tank shield bolts.
  11. Remove the fuel tank shield.
  12. Place a suitable adjustable jack under the fuel tank.
  13. Notice: Refer to Fuel Tank Strap Fastener Notice in the Preface section.


    Object Number: 877748  Size: SH
  14. Remove the fuel tank strap bolts.
  15. Remove the fuel tank straps.
  16. Lower the fuel tank.
  17. With the aid of an assistant, place the fuel tank in a suitable work area.
  18. Cap the fuel pipes in order to prevent possible fuel system contamination.
  19. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .

Installation Procedure


    Object Number: 877748  Size: SH
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps.
  6. 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.

  7. Install the fuel tank strap bolts.
  8. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).

  9. Remove the jack from under the fuel tank.

  10. Object Number: 877746  Size: SH
  11. Install the fuel tank shield.
  12. Install the fuel tank shield bolts.
  13. Tighten
    Tighten the bolts to 18 N·m (13 lb ft).

  14. Lower the vehicle.

  15. Object Number: 881567  Size: SH
  16. Connect the fuel feed/return pipes to the sending unit. Refer to Metal Collar Quick Connect Fitting Service .

  17. Object Number: 877754  Size: SH
  18. Connect the sending unit electrical connector (2).

  19. Object Number: 877741  Size: SH
  20. Install the fuel fill and vent hose to the tank.
  21. Tighten the fuel fill and vent hose clamps at the tank.
  22. Tighten
    Tighten the hose clamps to 2.5 N·m (22 lb in).

  23. Fill the fuel tank.
  24. Install the fuel fill cap.
  25. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  26. Command the fuel transfer pump on with a scan tool .
  27. Test for fuel leaks.