GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 1997 🢒 Yukon - 4WD 🢒 Engine 🢒 Engine Controls - 5.0L, 5.7L, and 7.4L 🢒 Fuel Tank Replacement

Fuel Tank Replacement Suburban

Removal Procedure

Tools Required

J 39765 Fuel Sender Locknut 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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

    4. Object Number: 18322 Size: SH
  4. Remove the fuel tank off-road shield, if equipped.

    5. Object Number: 18442 Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    6. Object Number: 18311 Size: SH
  6. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    7. Object Number: 18313 Size: SH
  7. Lower the fuel tank shield.

    8. Object Number: 18321 Size: SH
  8. Lower the fuel tank. Disconnect the fuel feed and vapor hoses. Disconnect the electrical connections at the sender.

    9. Object Number: 65287 Size: SH
  9. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.

    3. Object Number: 18321 Size: SH
  3. Completely raise the fuel tank.

    4. 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.

  4. Install the fuel tank straps and fastening hardware.

    5. Object Number: 18442 Size: SH
  5. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    6. Object Number: 18311 Size: SH

    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.

    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 fuel tank straps with insulator strips in place.

    7. Install the fuel tank strap bolts.

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


    Object Number: 18322 Size: SH
  7. Install the fuel tank off-road shield, if equipped.
  8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  9. 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.
  10. Check for leaks.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.

Fuel Tank Replacement Tahoe/Yukon

Removal Procedure

Tools Required

J 39765 fuel sender locknut wrench.

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

   • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
   • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

    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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Relieve the fuel system pressure. Refer to Fuel Tank Draining Procedure
  4. Raise the vehicle.

    5. Object Number: 18442 Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    6. Object Number: 18329 Size: SH
  6. Support the fuel tank and loosen the tank straps and remove insulator strips, if equipped.

    7. Object Number: 18321 Size: SH
  7. With the aid of an assistant lower and support the fuel tank and shield.
  8. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Disconnect the fuel feed and vapor hoses.
  9. Disconnect the electrical connections at the sender.
  10. Remove the fuel tank straps.
  11. Remove the fuel tank and place in a suitable work area.

    12. Object Number: 65287 Size: SH
  12. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. With the aid of an assistant, raise and support the tank to allow reconnection of the fuel feed and vapor hoses and the electrical connections at the sender.

    3. Object Number: 18321 Size: SH
  3. Raise the tank fully.
  4. Install the fuel tank straps and fastening hardware.

    5. 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.


    Object Number: 18442 Size: SH
  5. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    6. Object Number: 18329 Size: SH

    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.

    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 fuel tank straps with insulator strips in place.

    7. Tighten
    Tighten the strap nuts to 13 N·m (115 lb in).


    Object Number: 18318 Size: SH
  7. Install the fuel tank off-road shield, if equipped.
  8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  9. 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.
  10. Check for fuel leaks.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.

Fuel Tank Replacement Extended Cab - Side Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut 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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

    4. Object Number: 18442 Size: SH
  4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    5. Object Number: 18413 Size: SH
  5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    6. Object Number: 18414 Size: SH
  6. Lower the fuel tank shield.

    7. Object Number: 18415 Size: SH
  7. Lower the fuel tank.

    8. Object Number: 19204 Size: SH
  8. Disconnect the fuel feed (1) and vapor (2) hoses.
  9. Disconnect the electrical connections at the sender.

    10. Object Number: 65287 Size: SH
  10. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

    2. Object Number: 19204 Size: SH
  2. Raise the tank slightly and reconnect the fuel feed (1) vapor (2) hoses and the electrical connector at the sender.

    3. Object Number: 18415 Size: SH
  3. Raise the fuel tank fully.

    4. Object Number: 18414 Size: SH
  4. Install the fuel tank shield.
  5. Install the fuel tank straps and fastening hardware.

    6. 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.


    Object Number: 18442 Size: SH
  6. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    7. Object Number: 18413 Size: SH

    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.

    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 fuel tank brackets with insulator strips in place.

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

  8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  9. 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.
  10. Check for fuel leaks.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.

Fuel Tank Replacement Pick-up - Side Tank

Removal Procedure

Tools Required

J 39765 Fuel Sender Locknut 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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

    4. Object Number: 18442 Size: SH
  4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    5. Object Number: 18407 Size: SH
  5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    6. Object Number: 18406 Size: SH
  6. Remove the frame mounted bracket.

    7. Object Number: 18408 Size: SH
  7. Lower the fuel tank shield.

    8. Object Number: 18409 Size: SH
  8. Lower the fuel tank.

    9. Object Number: 19204 Size: SH
  9. Disconnect the fuel feed (1) and vapor (2) hoses. Disconnect the electrical connector at the sender.

    10. Object Number: 65287 Size: SH
  10. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

    2. Object Number: 19204 Size: SH
  2. Raise the tank slightly and reconnect the fuel feed (1), vapor (2) hoses and the electrical connector at the sender.

    3. Object Number: 18409 Size: SH
  3. Raise the fuel tank fully.

    4. Object Number: 18408 Size: SH
  4. Install the fuel tank shield.
  5. Install the fuel tank straps and fastening hardware.

    6. 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.


    Object Number: 18442 Size: SH
  6. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    7. Object Number: 18406 Size: SH
  7. Install the frame mounted bracket.

    8. Tighten
    Tighten the fasteners to 33 N·m(45 lb ft).


    Object Number: 18407 Size: SH

    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.

    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.

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

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

  9. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  10. 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.
  11. Check for fuel leaks.
    12. 11.1. Turn ON the ignition switch for 2 seconds.
    11.2. Turn OFF the ignition switch for 10 seconds.
    11.3. Again, turn the ignition switch to the ON position.
    11.4. Check for fuel leaks.

Fuel Tank Replacement Cab and Chassis - Side Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut 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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

    4. Object Number: 18440 Size: SH
  4. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    5. Object Number: 18418 Size: SH
  5. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    6. Object Number: 18419 Size: SH
  6. Lower the fuel tank shield.

    7. Object Number: 18420 Size: SH
  7. Lower the fuel tank.

    8. Object Number: 19204 Size: SH
  8. Disconnect the fuel feed (1) and vapor (2) hoses.
  9. Disconnect the electrical connections at the sender.

    10. Object Number: 65287 Size: SH
  10. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 65287 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .

    2. Object Number: 19204 Size: SH
  2. Raise the tank slightly and reconnect the fuel feed (1) vapor (2) hoses and the electrical connector at the sender.

    3. Object Number: 18420 Size: SH
  3. Raise the fuel tank fully.

    4. Object Number: 18419 Size: SH
  4. Install the fuel tank shield.
  5. Install the fuel tank straps and fastening hardware with insulator strips in place.

    6. 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.


    Object Number: 18440 Size: SH
  6. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    7. Object Number: 18418 Size: SH

    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.

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

  7. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  8. 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.
  9. Check for fuel leaks.
    10. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.

Fuel Tank Replacement Cab and Chassis - Rear Tank

Removal Procedure

Tools Required

J 39765 fuel sender locknut 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. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.

    4. Object Number: 421914 Size: SH
  4. Remove the fuel tank off-road shield, if equipped.

    5. Object Number: 18440 Size: SH
  5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.

    6. Object Number: 421915 Size: SH
  6. Support the fuel tank and remove the tank straps and insulator strips, if equipped.

    7. Object Number: 18425 Size: SH
  7. Lower the fuel tank.
  8. Disconnect the fuel feed and vapor hoses.
  9. Disconnect the electrical connections at the sender.

    10. Object Number: 421912 Size: SH
  10. Remove the fuel sender assembly and seal ring, using tool J 39765 . Discard the old seal ring.

Installation Procedure

    Object Number: 421912 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Raise the tank slightly and reconnect the fuel feed and vapor hoses and the electrical connections at the sender.

    3. Object Number: 18425 Size: SH
  3. Raise the fuel tank fully.
  4. Install the fuel tank straps and fastening hardware.

    5. 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.


    Object Number: 18440 Size: SH
  5. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

    6. Object Number: 421915 Size: SH

    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.

    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 fuel tank brackets with insulator strips in place.

    7. Tighten
    Tighten the strap bolts to 35 N·m (47 lb ft).


    Object Number: 421914 Size: SH
  7. Install the fuel tank off-road shield, if equipped.

    8. 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
    Tighten the fuel tank shield fastening hardware to 74 N·m(102 lb ft).

  8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
  9. 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.
  10. Check for fuel leaks.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Again, turn the ignition switch to the ON position.
    10.4. Check for fuel leaks.

Fuel Tank Replacement 4DR Utility

Removal Procedure
  1. Drain the fuel from the fuel tank. Refer to Fuel Tank Draining Procedure .
  2. Raise the vehicle. (This must be done with a frame hoist to allow the rear suspension to hang.)

    3. Object Number: 18431 Size: SH
  3. Remove the filler hose and vent hose from the fuel tank.

    4. Object Number: 18436 Size: SH
  4. Support the fuel tank and remove the fuel tank straps.

    5. Object Number: 18437 Size: SH
  5. Lower the fuel tank shield and the fuel tank.

    6. Object Number: 18448 Size: SH
  6. Disconnect the fuel feed and vapor hoses. Refer to Fuel Hose and Pipes (Quick Connect Fittings) .
  7. Disconnect the electrical connector at the sender.

    8. Object Number: 18438 Size: SH
  8. Remove the fuel tank.

    9. Object Number: 17407 Size: SH
  9. Remove the fuel sender and the seal ring, using tool J 39765 . Discard the old seal ring. Purge the tank, if the tank is being repaired.

Installation Procedure

    Object Number: 17407 Size: SH
  1. Install the new seal ring and reinstall the sender using tool J 39765 .
  2. Raise the tank and reconnect the electrical connector at the sender.

    3. Object Number: 18447 Size: SH
  3. Reconnect the fuel feed and vapor hoses. Refer to Fuel Hose and Pipes (Quick Connect Fittings) .

    4. Object Number: 18437 Size: SH
  4. Raise the tank fully and reinstall the tank shield.

    5. Object Number: 18436 Size: SH
  5. Reinstall the tank straps.

    6. Tighten
    Tighten the bolts to 12 N·m (10 lb ft).


    Object Number: 18432 Size: SH
  6. Reinstall the filler hose and the vent hose to the tank.
  7. Replenish the fuel. Reinstall the fuel tank filler cap.
  8. Reconnect the negative battery cable.
  9. Check for fuel leaks.
    10. 9.1. Turn ON the ignition switch for 2 seconds.
    9.2. Turn OFF the ignition switch for 10 seconds.
    9.3. Again, turn the ignition switch to the ON position.
    9.4. Check for fuel leaks.