GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2000 🢒 GMC K Pickup - 4WD 🢒 Engine 🢒 Engine Controls - 7.4L 🢒 Fuel Tank Replacement

Fuel Tank Replacement Rear Tank

Removal Procedure

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. (This must be done with a frame hoist to allow the rear suspension to hang.)

    5. Object Number: 590039 Size: SH
  5. Disconnect the fuel filler hose (7) and the vent hose (8) from the fuel tank.

    6. Object Number: 590054 Size: SH
  6. Support the fuel tank.
  7. Remove the fuel tank straps.

    8. Object Number: 590477 Size: SH
  8. With the aid of an assistant lower and support the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top of the fuel tank.
  9. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  10. Disconnect the fuel pipes (1) at the fuel sender (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  11. Disconnect the electrical connectors at the sender.

    12. Object Number: 590460 Size: SH
  12. Disconnect the EVAP pipe at the roll over valve pipe.

    13. Object Number: 18438 Size: SH
  13. Remove the fuel tank.
  14. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 590477 Size: SH
  1. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
  2. Raise the fuel tank.
  3. Connect the fuel pipes (1) at the fuel sender (2).

    4. Object Number: 590460 Size: SH
  4. Connect the EVAP pipe at the roll over valve pipe.
  5. Connect the fuel sender electrical connectors.

    6. Object Number: 18438 Size: SH
  6. Raise the fuel tank and shield fully.

    7. Object Number: 590054 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.

    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.

  7. Install the fuel tank straps.

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


    Object Number: 590039 Size: SH
  8. Connect the fuel filler hose (7) and the vent hose (8) to the fuel tank.

    9. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).

  9. Lower the vehicle.
  10. Refill the fuel system.
  11. Install the fuel filler cap.
  12. Connect the negative battery cable.
  13. Inspect for fuel leaks.
    14. 13.1. Turn ON the ignition for 2 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition.
    13.4. Inspect for fuel leaks.

Fuel Tank Replacement Extended Cab - Side Tank

Removal Procedure

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 590290 Size: SH
  5. Disconnect the fuel tank filler neck hose (2) from the fuel tank.
  6. Disconnect the fuel tank vent hose (3) from the fuel tank.

    7. Object Number: 589990 Size: SH
  7. Support the fuel tank.
  8. Remove the rear fuel tank strap.

    9. Object Number: 590007 Size: SH
  9. Remove the frame mounted bracket and front fuel tank strap.

    10. Object Number: 18409 Size: SH
  10. With the aid of an assistant lower and support the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top of the fuel tank.

    11. Object Number: 19204 Size: SH
  11. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  12. Disconnect the fuel pipes (1) and the vapor pipe (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  13. Disconnect the electrical connections at the sender.
  14. Remove the fuel tank and shield.
  15. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 589964 Size: SH
  1. Install the fuel tank insulators.

    2. Object Number: 19204 Size: SH
  2. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
  3. Raise the fuel tank.
  4. Connect the fuel pipes (1) and the vapor pipe (2) at the sender.
  5. Connect the electrical connections at the sender.

    6. Object Number: 590007 Size: SH
  6. Raise the fuel tank and shield fully.

    7. 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.

    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.

  7. Install the front fuel tank strap and the frame mounted bracket.

    8. Tighten

        • Tighten the front strap nut to 13 N·m (115 lb in).
        • Tighten the frame mounted bracket nuts to 33 N·m (24 lb ft).

    Object Number: 589990 Size: SH
  8. Install the rear fuel tank strap.

    9. Tighten
    Tighten the rear strap bolt to 13 N·m (115 lb in).


    Object Number: 590290 Size: SH
  9. Connect the fuel tank filler neck hose (2) to the fuel tank.
  10. Connect the fuel tank vent hose (3) to the fuel tank.

    11. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).

  11. Lower the vehicle.
  12. Refill the fuel system.
  13. Install the fuel filler cap.
  14. Connect the negative battery cable.
  15. Inspect for fuel leaks.
    16. 15.1. Turn ON the ignition for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition.
    15.4. Inspect for fuel leaks.

Fuel Tank Replacement Pick-Up Side Tank

Removal Procedure

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 590290 Size: SH
  5. Disconnect the fuel tank filler neck hose (2) from the fuel tank.
  6. Disconnect the fuel tank vent hose (3) from the fuel tank.

    7. Object Number: 590031 Size: SH
  7. Support the fuel tank.
  8. Remove the fuel tank straps.
  9. With the aid of an assistant lower and support the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top of the fuel tank.

    10. Object Number: 19204 Size: SH
  10. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  11. Disconnect the fuel pipes (1) and the vapor pipe (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  12. Disconnect the electrical connections at the sender.
  13. Remove the fuel tank and shield.
  14. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 589964 Size: SH
  1. Install the fuel tank insulators.

    2. Object Number: 19204 Size: SH
  2. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
  3. Raise the fuel tank.
  4. Connect the fuel pipes (1) and the vapor pipe (2) at the sender.
  5. Connect the electrical connections at the sender.

    6. Object Number: 590031 Size: SH
  6. Raise the fuel tank and shield fully.

    7. 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.

    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.

  7. Install the fuel tank straps and fastening hardware.

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


    Object Number: 590290 Size: SH
  8. Connect the fuel tank filler neck hose (2) to the fuel tank.
  9. Connect the fuel tank vent hose (3) to the fuel tank.

    10. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).

  10. Lower the vehicle.
  11. Refill the fuel system.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable.
  14. Inspect for fuel leaks.
    15. 14.1. Turn ON the ignition for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition.
    14.4. Inspect for fuel leaks.

Fuel Tank Replacement Cab and Chassis - Side Tank

Removal Procedure

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut 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. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    5. Object Number: 18440 Size: SH
  5. Disconnect the filler neck hose and the vent hose at the fuel filler tube.

    6. Object Number: 589981 Size: SH
  6. Support the fuel tank.
  7. Remove the fuel tank straps.

    8. Object Number: 18420 Size: SH
  8. With the aid of an assistant lower the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top of the fuel tank.

    9. Object Number: 590450 Size: SH
  9. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  10. Disconnect the fuel pipes (1,3) and the vapor pipe (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  11. Disconnect the electrical connections at the sender.
  12. Remove the fuel tank and shield.
  13. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 589961 Size: SH
  1. Install the fuel tank insulators.

    2. Object Number: 590450 Size: SH
  2. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
  3. Raise the fuel tank.
  4. Connect the fuel pipes (1,3) and the vapor pipe (2) to the fuel sender.
  5. Connect the electrical connections at the sender.

    6. Object Number: 18420 Size: SH
  6. Raise the fuel tank and shield fully.

    7. Object Number: 589981 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.

    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.

  7. Install the fuel tank straps.

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


    Object Number: 18440 Size: SH
  8. Connect the filler neck hose and the vent hose to the fuel filler tube.

    9. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).

  9. Lower the vehicle.
  10. Refill the fuel system.
  11. Install the fuel filler cap.
  12. Connect the negative battery cable.
  13. Inspect for fuel leaks.
    14. 13.1. Turn ON the ignition for 2 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition.
    13.4. Inspect for fuel leaks.

Fuel Tank Replacement Cab and Chassis - Rear Tank

Removal Procedure

Tools Required

    • J 34730-1A Fuel Pressure Gauge
    • J 39765 Fuel Sender Lock Nut 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. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel from the tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 421914 Size: SH
  5. Remove the fuel tank shield.

    6. Object Number: 18440 Size: SH
  6. Disconnect the filler neck hose and the vent hose at the fuel filler tube.

    7. Object Number: 421915 Size: SH
  7. Support the fuel tank.
  8. Remove the fuel tank straps.

    9. Object Number: 18425 Size: SH
  9. With the aid of an assistant lower and support the fuel tank. Lower the fuel tank to access the top of the fuel tank.
  10. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  11. Disconnect the fuel pipes and the vapor pipe. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  12. Disconnect the electrical connections at the sender.
  13. Remove the fuel tank.
  14. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 18425 Size: SH
  1. Install the fuel sender. Refer to Fuel Sender Assembly Replacement .
  2. Raise the fuel tank.
  3. Connect the fuel pipes and the vapor pipe at the sender.
  4. Connect the electrical connections at the sender.
  5. Raise the fuel tank fully.

    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.


    Object Number: 421915 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.

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


    Object Number: 421914 Size: SH
  7. Install the fuel tank shield.

    8. Tighten
    Tighten the fuel tank shield fastening hardware to 75 N·m(55 lb ft).


    Object Number: 18440 Size: SH
  8. Connect the filler neck hose and the vent hose to the fuel filler tube.

    9. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).

  9. Lower the vehicle.
  10. Refill the fuel system.
  11. Install the fuel filler cap.
  12. Connect the negative battery cable.
  13. Inspect for fuel leaks.
    14. 13.1. Turn ON the ignition for 2 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition.
    13.4. Inspect for fuel leaks.