GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2000 🢒 GMC K Sierra - 4WD 🢒 General Information 🢒 General Information 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 300318 Size: SH

    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 tank. Refer to Fuel Tank Draining .
  4. Disconnect the fuel fill pipe from the fuel fill pipe housing.

    5. 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.

  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    6. Object Number: 420291 Size: SH
  6. Disconnect the fuel fill pipe ground strap.

    7. Object Number: 303981 Size: SH
  7. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .

    8. Object Number: 303903 Size: SH
  8. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  9. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

    11. Object Number: 373155 Size: SH
  11. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.

    12. Object Number: 300138 Size: SH
  12. With the aid of an assistant, support the fuel tank.
  13. Remove the fuel tank strap attaching bolts.
  14. Remove the fuel tank straps.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.

    17. Object Number: 396067 Size: SH
  17. Remove the fuel feed pipe (4) and the fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
  18. Remove the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).

    19. Object Number: 386369 Size: MH
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Remove the fuel fill and vent hose and pipe assembly from the fuel tank.

Installation Procedure

    Object Number: 386369 Size: MH
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

    2. 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.

  2. Install the fuel fill and vent hose and pipe assembly to the fuel tank.

    3. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in.).


    Object Number: 396067 Size: SH
  3. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
  4. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender (2) and the retaining clips (6).

    5. Object Number: 300138 Size: SH
  5. With the aid of an assistant, position and support the fuel tank.
  6. Install the fuel tank straps.

    7. 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 strap attaching bolts.

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


    Object Number: 373155 Size: SH
  8. Connect the fuel sender and the fuel pressure sensor electrical connectors.

    9. Object Number: 303903 Size: SH
  9. Remove the caps from the fuel and EVAP pipes.
  10. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .

    11. Object Number: 303981 Size: SH
  11. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .

    12. Object Number: 420291 Size: SH
  12. Connect the fuel fill pipe ground strap.

    13. Tighten
    Tighten the fuel fill pipe ground strap bolt to 9 N·m (80 lb in.).

  13. Lower the vehicle.

    14. Object Number: 300318 Size: SH
  14. Connect the fuel fill pipe to the fuel fill pipe housing.

    15. Tighten
    Tighten the fuel fill pipe housing screws to 2.3 N·m (20 lb in.).

  15. Refill the fuel tank.
  16. Tighten the fuel filler cap.
  17. Connect the negative battery cable.
  18. Inspect for leaks.
    19. 18.1. Turn the ignition ON for 2 seconds.
    18.2. Turn the ignition OFF for 10 seconds.
    18.3. Turn the ignition ON.
    18.4. Inspect for fuel leaks.