Fuel Tank Replacement Suburban

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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 cables.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining .
3. Raise the vehicle.



4. Remove the bolts and the fuel tank off-road shield, if equipped.



5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



6. Support the fuel tank and remove the tank strap bolts, the tank straps and the insulator strips, if equipped.



7. Lower the fuel tank and shield enough to access the fuel lines and electrical connections at the tank and sender.
8. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.
9. Lower the tank and shield fully.
10. Lift the tank out of the shield and place the tank on the floor.



11. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring and reinstall the sender using the J 36608 fuel sender tool.
2. Place the tank in the shield.
3. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.



4. Raise the tank and shield fully.



5. Reinstall the fuel tank filler neck to the tank.

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. Install the clamp

Tighten
Tighten the clamp to 2.5 N·m (25 lb in).





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.

7. Install the fuel tank brackets with insulator strips in place.

Tighten
Tighten the strap bolts to 45 N·m (33 lb ft).




8. Install the fuel tank off-road shield, if equipped.
9. Install the bolts.

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

10. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
11. 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.
12. Check for leaks.

12.1.

Turn ON the ignition switch for 2 seconds.

12.2.

Turn OFF the ignition switch for 10 seconds.

12.3.

Again, turn the ignition switch to the ON position.

12.4.

Check for fuel leaks.

Fuel Tank Replacement Tahoe/Yukon

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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



4. Remove the fuel tank off-road shield bolts and the fuel tank off-road shield, if equipped.



5. Loosen the filler neck hose clamp at the fuel tank.
6. Disconnect the fuel tank filler neck from the fuel tank.



7. Support the fuel tank and remove the tank strap bolts, the tank straps, and the insulator strips, if equipped.



8. Lower the fuel tank and shield enough to access the fuel lines and electrical connections at the tank and sender.
9. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.
10. Lower the tank and shield fully.
11. Lift the tank out of the shield and place the tank on the floor.



12. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring and reinstall the sender using the J 36608 fuel sender tool.
2. Place the tank in the shield.
3. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.



4. Raise the tank and shield fully.



5. Reinstall the fuel tank filler neck to the tank.

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. Install the clamp.

Tighten
Tighten the clamp to 2.5 N·m (25 lb in).





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.

7. Install the fuel tank brackets with insulator strips in place.

Tighten
Tighten the strap bolts to 45 N·m (33 lb ft).




8. Install the fuel tank off-road shield, if equipped.
9. Install the bolts.

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

10. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
11. 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.
12. Check for fuel leaks.

12.1.

Turn ON the ignition switch for 2 seconds.

12.2.

Turn OFF the ignition switch for 10 seconds.

12.3.

Again, turn the ignition switch to the ON position.

12.4.

Check for fuel leaks.

Fuel Tank Replacement Pickup Side Tank

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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. Remove negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining .
3. Raise the vehicle.



4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



5. Support the fuel tank and remove the tank strap fasteners and insulator strips, if equipped.



6. Remove the nuts from the frame mounted bracket.
7. Remove the frame mounted bracket.



8. Lower the fuel tank and shield enough to access the fuel lines and electrical connections at the tank and sender.



9. Disconnect the fuel hoses and lines. Disconnect the electrical connections at the sender.
10. Lower the tank and shield completely.
11. Lift the tank out of the shield and place the tank on the floor.



12. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to reinstall the sender.
3. Place the tank in the shield.



4. Raise the tank and shield slightly and reconnect the fuel hoses, the lines, and the electrical connections at the sender.



5. Raise the tank and shield fully.



6. Reinstall the fuel tank filler neck on to the tank.

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 clamp.

Tighten
Tighten the clamp to 2.5 N·m (25 lb in).




8. Install the frame mounted bracket.
9. Install the nuts.

Tighten
Tighten the nuts to 33 N·m (25 lb ft).




10. Install the fuel tank brackets with the insulator strips in place.

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.

11. Tighten the strap bolts.

Tighten
Tighten the strap bolts to 45 N·m (33 lb ft).

12. Replenish the fuel in the tank.
13. Reinstall the fuel tank filler cap.
14. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all of the devices that lost their memory after the battery was disconnected.
15. Check for leaks.

15.1.

Turn ON the ignition switch for 2 seconds.

15.2.

Turn OFF the ignition switch for 10 seconds.

15.3.

Again, turn the ignition switch to the ON position.

15.4.

Check for fuel leaks.

Fuel Tank Replacement Cab and Chassis Side Tank

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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



4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.



6. Lower the fuel tank and shield enough to access the fuel lines and electrical connections at the tank and sender.



7. Disconnect the fuel hoses and lines. Disconnect the electrical connections at the sender.
8. Lower the tank and shield fully.
9. Lift the tank out of the shield and place the tank on the floor.



10. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to reinstall the sender.
3. Place the tank in the shield.



4. Raise the tank and shield slightly and reconnect the fuel hoses (1), the lines, and the electrical connections at the sender.



5. Raise the tank and shield fully.



6. Reinstall the fuel tank filler neck to the tank.

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 clamp.

Tighten
Tighten the clamp to 2.5 N·m (25 lb in).





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.

8. Install the fuel tank brackets with the insulator strips in place.
9. Tighten the strap bolts.

Tighten
Tighten the strap bolts to 45N·m (33 lb ft).

10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
12. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
13. Check for leaks.

13.1.

Turn ON the ignition switch for 2 seconds.

13.2.

Turn OFF the ignition switch for 10 seconds.

13.3.

Again, turn the ignition switch to the ON position.

13.4.

Check for fuel leaks.

Fuel Tank Replacement Cab and Chassis Rear Tank

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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



4. Remove the fuel tank off-road shield bolts, if equipped.
5. Remove the fuel tank off-road shield, if equipped.



6. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



7. Support the fuel tank and remove the tank straps and insulator strips, if equipped.



8. Lower the fuel tank enough to access the fuel lines and electrical connections on the tank and sender.
9. Disconnect the fuel hoses and lines. Disconnect the electrical connections at the sender.
10. Lower the tank fully.



11. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to reinstall the sender.
3. Raise the tank slightly and reconnect the fuel hoses, the lines, and the electrical connections at the sender.



4. Raise the tank fully.



5. Reinstall the fuel tank filler neck to the tank.

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. Install the clamp.

Tighten
Tighten the clamp to 2.5 N·m (25 lb in).




7. Install the fuel tank brackets with the insulator strips in place.

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.

8. Tighten the strap bolts.

Tighten
Tighten the strap bolts to 45N·m (33 lb ft).




9. Install the fuel tank off-road shield, if equipped.
10. Install the fuel tank off-road shield bolts, if equipped.

Tighten
Tighten the bolts to 11 N·m (100 lb in).

11. Replenish the fuel in the tank.
12. Reinstall the fuel tank filler cap.
13. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
14. Check for leaks.

14.1.

Turn ON the ignition switch for 2 seconds.

14.2.

Turn OFF the ignition switch for 10 seconds.

14.3.

Again, turn the ignition switch to the ON position.

14.4.

Check for fuel leaks.

Fuel Tank Replacement Extended Cab Side Tank

Removal Procedure

Tools Required

J 36608 Fuel Sender Tool

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 negative battery cables.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining .

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

3. Raise the vehicle.



4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.



5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.



6. Lower the fuel tank and shield enough to access the fuel lines and electrical connections on the tank and sender.



7. Disconnect the fuel hoses and lines. Disconnect the electrical connections at the sender.
8. Lower the tank and shield fully.
9. Lift the tank out of the shield and place the tank on the floor.



10. Remove the fuel sender assembly and seal ring, using the J 36608 fuel sender tool. Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to reinstall the sender.
3. Place the tank in the shield.



4. Raise the tank and shield slightly and reconnect the fuel hoses, the lines, and the electrical connections at the sender.



5. Raise the tank and shield fully.



6. Reinstall the fuel tank filler neck to the tank.

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 clamp.

Tighten
Tighten the clamp to 2.5 N·m (100 lb in).




8. Install the fuel tank brackets with insulator strips in place.

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.

9. Tighten the strap bolts.

Tighten
Tighten the strap bolts to 45N·m (33 lb ft).

10. Replenish the fuel in the tank.
11. Reinstall the fuel tank filler cap.
12. 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.
13. Check for leaks.

13.1.

Turn ON the ignition switch for 2 seconds.

13.2.

Turn OFF the ignition switch for 10 seconds.

13.3.

Again, turn the ignition switch to the ON position.

13.4.

Check for fuel leaks.