Fuel Tank Replacement (Single Tank)

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
5. Remove the Evaporative Emission (EVAP) canister.
6. Disconnect the chassis fuel pipes (2) at the fuel tank pipes (1).
7. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.




8. Disconnect the EVAP vent pipe at the fuel tank clip (5).




9. Loosen the vent hose clamp (4).
10. Disconnect the vent hose from the vent pipe.




11. With the aid of an assistant, support the fuel tank.

NOTE: Refer to Fuel Tank Straps Notice in Cautions and Notices.

12. Remove the fuel tank strap attaching bolts.
13. Remove the fuel tank straps.
14. Carefully lower the rear of the fuel tank slightly.
15. Remove the fuel sender cover on the Suburban only.




16. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
17. Remove the fuel tank.
18. Place the fuel tank in a suitable work area.




19. Remove the fuel feed and return pipes (3) from the fuel sender and the retaining clips.
20. Remove the fuel sender assembly from the fuel tank.
21. Remove the EVAP pipe from the fuel tank roll over valves (2) (4) and the retaining clips (1).
22. Remove the fuel fill hose and the vent hose from the fuel tank.

INSTALLATION PROCEDURE




1. Connect the EVAP pipe to the fuel tank roll over valves (2) (4) and the retaining clips (1).
2. Install the fuel sender assembly to the fuel tank.
3. Connect the fuel feed and return pipes (3) to the fuel sender and the retaining clips.

NOTE: Refer to Fastener Notice in Cautions and Notices.

4. Install the fuel fill hose and the vent hose to the fuel tank.

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




5. With the aid of an assistant, support and partially raise the fuel tank front end first.
6. Connect the fuel sender and the fuel pressure sensor electrical connectors.
7. Install the fuel sender cover on the Suburban only.




8. Fully raise the fuel tank.
9. Install the fuel tank straps.
10. Install the fuel tank strap attaching bolts.

Tighten
Tighten the bolts to 40 N.m (30 lb ft).




11. Connect the fuel fill hose and the vent hose to the pipes.

Tighten
^ Tighten the fuel fill hose clamp (2) to 2.5 N.m (22 lb in).
^ Tighten the vent hose clamp (4) to 2.5 N.m (22 lb in).




12. Connect the EVAP vent pipe to the fuel tank clip (5).




13. Remove the caps from the fuel and EVAP pipes.
14. Connect the chassis fuel pipes (2) at the fuel tank pipes (1).
15. Install the EVAP canister.
16. Lower the vehicle.
17. Refill the fuel tank.
18. Install the fuel filler cap.
19. Connect the negative battery cable.
20. Inspect for leaks.
20.1. Turn the ignition ON for 2 seconds.
20.2. Turn the ignition OFF for 10 seconds.
20.3. Turn the ignition ON.
20.4. Inspect for fuel leaks.