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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .



4. Remove the fuel tank and sender assembly.

•	Fuel Tank Replacement (Tahoe/Yukon) for the Tahoe/Yukon.

•	Fuel Tank Replacement (Suburban)for the Suburban.

•	Fuel Tank Replacement (Extended Cab - Side Tank) for the extended cab (side tank)

•	Fuel Tank Replacement (Pick-up - Side Tank) for the pick-up side tank

•	Fuel Tank Replacement (Cab and Chassis - Side Tank) for the cab and chassis- side tank

•	Fuel Tank Replacement (Cab and Chassis - Rear Tank) for the cab and chassis - rear tank.

•	Fuel Tank Replacement for the 4DR Utility.

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.

1. Install a new seal, sending assembly and lock ring. Make sure the lock ring alignment notches fit over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
3. Install the fuel tank.

•	Fuel Tank Replacement (Tahoe/Yukon) for the Tahoe/Yukon.

•	Fuel Tank Replacement (Suburban)for the Suburban.

•	Fuel Tank Replacement (Extended Cab - Side Tank) for the extended cab (side tank)

•	Fuel Tank Replacement (Pick-up - Side Tank) for the pick-up side tank

•	Fuel Tank Replacement (Cab and Chassis - Side Tank) for the cab and chassis- side tank

•	Fuel Tank Replacement (Cab and Chassis - Rear Tank) for the cab and chassis - rear tank.

•	Fuel Tank Replacement for the 4DR Utility.

4. Add fuel removed from the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.