GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 1999 🢒 Unit Repair 🢒 Engine 🢒 Engine Controls - 6.5L 🢒 Fuel Tank Replacement

Removal Procedure

Tools Required

Fuel Sender Lock Nut 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.


    Object Number: 300178 Size: SH
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure by removing the filler cap.
  3. Drain the fuel tank. Refer to
  4. Clean all the fuel pipe and fuel hose connections and surrounding areas before disconnecting the fuel pipes and the fuel hoses in order to avoid possible contamination of the fuel system.
  5. Raise the vehicle.
  6. Loosen the fuel fill hose to fuel tank clamp (4).
  7. Disconnect the fuel fill hose (3) from the fuel tank.

    8. Object Number: 303903 Size: SH
  8. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.
  9. Cap the fuel pipes in order to prevent possible fuel system contamination.

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

    11. Object Number: 300138 Size: SH
  11. With the aid of an assistant, support the fuel tank.

    12. Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

  12. Remove the fuel tank strap attaching bolts.
  13. Remove the fuel tank straps.
  14. Remove the fuel tank.
  15. Place the fuel tank in a suitable work area.

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

    18. Object Number: 386369 Size: MH
  18. Remove the fuel sender assembly from the fuel tank. Refer to

Installation Procedure

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

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

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

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


    Object Number: 373155 Size: SH
  7. Connect the fuel sender electrical connectors.

    8. Object Number: 303903 Size: SH
  8. Remove the caps from the fuel pipes.
  9. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes.

    10. Object Number: 300178 Size: SH
  10. Connect the fuel fill hose (3) to the fuel tank.

    11. Tighten
    Tighten the fuel fill hose clamp (4) to 2.5 N·m (22 lb in).

  11. Lower the vehicle.
  12. Refill the fuel tank.
  13. Install the fuel filler cap.
  14. Connect the negative battery cable.
  15. Inspect for leaks by using the scan tool to activate the fuel lift pump.