Fuel Tank Replacement Front Tank
Removal Procedure
- Relieve the fuel system
pressure. Refer to
Fuel Pressure Relief
.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the evaporative emission (EVAP) canister. Refer to
Evaporative Emission Canister Replacement
.
- Disconnect the EVAP vent
pipe (3) at the fuel tank clip (5).
- Loosen the vent hose clamp
(7).
- Disconnect the vent hose (6) from the fuel tank.
- Disconnect the fuel fill
hose (2) from the fuel tank.
- With the aid of an assistant,
support the fuel tank.
- Remove the fuel tank strap attaching bolts.
- Remove the fuel tank straps.
- Carefully lower the rear of the fuel tank slightly.
- Remove the fuel sender cover, on the suburban only.
- Disconnect the fuel feed,
return, and evaporative emission (EVAP) pipes (1, 2, 3) at
the fuel sender.
- Disconnect the fuel sender and the fuel pressure sensor electrical
connectors.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Disconnect the EVAP pipe
from the fuel tank roll over valves (2, 4) and the retaining clips
(1).
- Remove the fuel sender assembly from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Cap the fuel and EVAP pipes in order to prevent possible fuel
system contamination.
Installation Procedure
- Connect the EVAP pipe
to the fuel tank roll over valves (2, 4) and the retaining clips (1).
- Install the fuel sender assembly to the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- With the aid of an assistant,
support and partially raise the fuel tank front end first.
- Connect the fuel sender and the fuel pressure sensor electrical
connectors.
- Connect the fuel feed, return, and EVAP pipes (1, 2, 3)
at the fuel sender.
- Install the fuel sender cover, on the suburban only.
- Fully raise the fuel tank.
- Install the fuel tank straps.
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.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Connect the vent hose
(6) to the fuel tank.
Tighten
Tighten the vent hose clamp (7) to 2.5 N·m (22 lb
in)
- Connect the fuel fill
hose (2) to the fuel tank.
Tighten
Tighten the fuel fill hose clamp (1) to 2.5 N·m (22 lb
in)
- Connect the EVAP vent
pipe to the fuel tank clip (5).
- Install the EVAP canister.
Refer to
Evaporative Emission Canister Replacement
.
- Lower the vehicle.
- Refill the fuel tank.
- Install the fuel filler cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks using the following procedure:
18.1. | Turn ON the ignition, with the engine OFF, for 2 seconds. |
18.2. | Turn OFF the ignition for 10 seconds. |
18.3. | Turn ON the ignition, with the engine OFF. |
18.4. | Inspect for fuel leaks. |
- Install the engine sight shield.
Fuel Tank Replacement Rear Tank
Removal Procedure
- Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief
.
- Lower and remove the under chassis mounted spare tire.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the rear exhaust hanger bolts and hanger.
- Remove the rear crossmember that holds the spare tire.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Loosen the fuel tank filler
hose clamp at the front tank.
- Remove the filler hose from the front tank, and reposition the
hose towards the rear tank.
- Remove the fuel pipe ground
strap bolt.
- Separate the ground straps (1, 2).
- Loosen the fuel tank filler
pipe hose clamp at the rear tank.
- Separate the filler pipe from the rear tank.
- Loosen the vent hose clamp
(2) at the vent pipe (1).
- Remove the vent hose (3) from the vent pipe (1).
- Lower the vehicle.
- Remove the fuel tank filler
housing to body screws (1) and retainer (2).
- Remove the fuel tank filler
housing to fuel tank filler pipe screws.
- Remove the fuel tank filler housing from the vehicle.
- Remove the fuel filler pipe from the vehicle.
- Raise the vehicle.
- Support the fuel tank with a suitable jack.
- Remove the fuel tank strap
bolts.
- Remove the fuel tank straps.
- Partially lower the rear tank.
- Loosen the fuel tank filler
hose clamp at the rear tank.
- Remove the filler hose from the rear tank.
- Disconnect the evaporative
emission (EVAP) tubes (2) at the EVAP pipes.
- Disconnect the fuel pipe at the fuel sender (1). Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel and EVAP pipes in order to prevent possible fuel
system contamination.
- Disconnect the fuel tank
electrical connector.
- Lower the fuel tank.
- With the aid of an assistant, remove the tank from the jack.
- Remove the fuel sender assembly, if required. Refer to
Fuel Sender Assembly Replacement
.
- Remove the EVAP pipes
from the fuel tank roll over valves (1, 3) and the retaining clips (2), if
required.
Installation Procedure
- Install the EVAP pipes
to the fuel tank roll over valves (1, 3) and the retaining clips (2), if
required.
- Install the fuel sender assembly, if required. Refer to
Fuel Sender Assembly Replacement
.
- With the aid of an assistant, install the tank to the jack.
- Partially raise the fuel tank.
- Connect the fuel tank
electrical connector.
- Remove the caps from the
fuel and EVAP pipes.
- Connect the fuel pipe at the fuel sender (1).
- Connect the EVAP tubes (2) at the EVAP pipes.
- Install the filler hose
to the rear tank.
- Position the hose clamp screw downwards, for easy access.
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.
- Tighten the fuel tank filler hose clamp at the rear tank.
Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).
- Completely raise and install
the tank.
- Install the fuel tank straps.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Remove the jack from the fuel tank.
- Lower the vehicle.
- Install the fuel filler
pipe to the vehicle.
- Install the fuel tank filler housing to the vehicle.
- Install the fuel tank filler housing to fuel tank filler pipe
screws.
Tighten
Tighten the screws to 2.3 N·m (20 lb in).
- Install the fuel tank
filler housing to body screws (1) and retainer (2).
Tighten
Tighten the screws to 2.3 N·m (20 lb in).
- Raise the vehicle.
- Install the vent hose
(3) to the vent pipe (1).
- Tighten the vent hose clamp (2) at the vent pipe (1).
Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).
- Connect the filler pipe
to the rear tank.
- Tighten the fuel tank filler pipe hose clamp at the rear tank.
Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).
- Align and position the
chassis wiring harness ground strap (2) and fuel filler pipe ground strap
(1).
- Install the fuel pipe ground strap bolt.
Tighten
Tighten the bolt to 9 N·m (80 lb in).
- Install the filler hose
to the front tank.
- Tighten the fuel tank filler hose clamp at the front tank.
Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).
- Install the rear crossmember that holds the spare tire.
- Install the rear exhaust hanger bolts and hanger.
- Lower the vehicle.
- Install and raise the under chassis mounted spare tire.
Fuel Tank Replacement Cab/Chassis Front
Removal Procedure
- Relieve the fuel system
pressure. Refer to the
Fuel Pressure Relief
.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank shield (1).
- Disconnect the fuel fill
and vent pipe (2) from the fuel tank.
- With the aid of an assistant,
support the fuel tank.
- Remove the fuel tank strap attaching bolts.
- Remove the fuel tank straps (1).
- Carefully lower the fuel tank slightly.
- Disconnect the fuel and EVAP pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Disconnect the fuel sender and the fuel pressure sensor harness
connectors.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel sender assembly from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Cap the fuel and EVAP pipes on the vehicle in order to prevent
possible fuel system contamination.
Installation Procedure
- Install the fuel sender
assembly to the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Remove the caps from the fuel and EVAP pipes.
- With the aid of an assistant, support and partially raise the
fuel tank.
- Connect the fuel sender and the fuel pressure sensor harness
connectors.
- Connect the fuel and EVAP pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Fully raise the fuel tank (2).
- Install the fuel tank straps (1).
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.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Connect the fuel fill
and vent pipe (2) to the fuel tank.
Tighten
Tighten the hose clamps to 2.5 N·m (22 lb in).
- Install the fuel tank
shield (1).
- Lower the vehicle.
- Refill the fuel tank (2).
- Install the fuel filler cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks using the following procedure:
15.1. | Turn ON the ignition, with the engine OFF, for 2 seconds. |
15.2. | Turn OFF the ignition for 10 seconds. |
15.3. | Turn ON the ignition with the engine OFF. |
15.4. | Inspect for fuel leaks. |
- Install the engine sight shield.
Fuel Tank Replacement Cab/Chassis Rear
Removal Procedure
- Relieve the fuel system
pressure. Refer to the
Fuel Pressure Relief
.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank shield (2).
- Disconnect the fuel fill
and vent pipe (1) from the fuel tank.
- With the aid of an assistant,
support the fuel tank.
- Remove the fuel tank strap attaching bolts (2).
- Remove the fuel tank straps (3).
- Carefully lower the fuel tank slightly.
- Disconnect the fuel and evaporative emission (EVAP) pipes. Refer
to
Metal Collar Quick Connect Fitting Service
.
- Disconnect the fuel sender and the fuel pressure sensor harness
connectors.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel sender assembly from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Cap the fuel and EVAP pipes in order to prevent possible fuel
system contamination.
Installation Procedure
- Install the fuel sender
assembly to the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Remove the caps from the fuel and EVAP pipes.
- With the aid of an assistant, support and partially raise the
fuel tank.
- Connect the fuel sender and the fuel pressure sensor harness
connectors.
- Connect the fuel and EVAP pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Fully raise the fuel tank.
- Install the fuel tank straps (3).
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.
- Install the fuel tank strap bolts (2).
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Connect the fuel fill
and vent pipe (1) to the fuel tank.
Tighten
Tighten the fuel fill hose clamps to 2.5 N·m (22 lb
in).
- Install the fuel tank
shield (2).
- Lower the vehicle.
- Refill the fuel tank.
- Install the fuel filler cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks using the following procedure:
15.1. | Turn ON the ignition, with the engine OFF, for 2 seconds. |
15.2. | Turn OFF the ignition for 10 seconds. |
15.3. | Turn ON the ignition, with the engine OFF. |
15.4. | Inspect for fuel leaks. |
- Install the fuel injection sight shield.
Fuel Tank Replacement Pickup
Removal Procedure
- Relieve the fuel system
pressure. Refer to the
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Disconnect the fuel fill pipe from the fuel fill pipe housing.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Disconnect the fuel fill
pipe ground strap.
- Remove the evaporative
emission (EVAP) canister. Refer to
Evaporative Emission Canister Replacement
.
- 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
.
- Cap the fuel and EVAP pipes in order to prevent possible fuel
system contamination.
- Disconnect the fuel sender
and the fuel pressure sensor electrical connectors.
- Remove the fuel tank shield.
- With the aid of an assistant,
support the fuel tank.
- Remove the fuel tank strap attaching bolts.
- Remove the fuel tank straps.
- Remove the fuel tank.
- Place the fuel tank in a suitable work area.
- Remove the fuel feed pipe (4)
and the fuel return pipe (5) from the fuel sender (2) and the
retaining clips (6).
- Remove the EVAP pipe (1) from the fuel sender (2),
the fuel tank roll over valve (3), and the retaining clips (6).
- Remove the fuel sender assembly from the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
- Remove the fuel fill and vent hose and pipe assembly from the
fuel tank.
Installation Procedure
- Install the fuel sender assembly to the fuel tank. Refer to
Fuel Sender Assembly Replacement
.
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.
- Install the fuel fill and vent hose and pipe assembly to the fuel tank.
Tighten
Tighten the hose clamp to 2.5 N·m (22 lb in).
- Connect the EVAP pipe (1)
to the fuel sender (2), the fuel tank roll over valve (3), and
the retaining clips (6).
- Connect the fuel feed pipe (4) and the fuel return pipe (5)
to the fuel sender and the retaining clips.
- With the aid of an assistant,
position and support the fuel tank.
- Install the fuel tank straps.
- Install the fuel tank strap bolts.
Tighten
Tighten the bolts to 40 N·m (30 lb ft).
- Install the fuel tank
shield to the fuel tank clips.
- Install the fuel tank
shield to frame bolts.
Tighten
Tighten the bolts to 18 N·m (13 lb ft).
- Connect the fuel sender
and the fuel pressure sensor electrical connectors.
- Remove the caps from the
fuel and EVAP pipes.
- 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
.
- Install the EVAP canister.
Refer to
Evaporative Emission Canister Replacement
.
- Connect the fuel fill
pipe ground strap.
Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N·m (80 lb in).
- Lower the vehicle.
- Connect the fuel fill
pipe to the fuel fill pipe housing.
Tighten
Tighten the fuel fill pipe housing screws to 2.3 N·m (20 lb
in).
- Refill the fuel tank.
- Install the fuel filler cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Inspect for leaks using the following procedure:
20.1. | Turn ON the ignition, with the engine OFF, for 2 seconds. |
20.2. | Turn OFF the ignition for 10 seconds. |
20.3. | Turn ON the ignition, with the engine OFF. |
20.4. | Inspect for fuel leaks. |
- Install the engine sight shield.