Removal & Installation (Cutaway Van Side Tank)
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect the negative battery cable. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank. Raise and support the vehicle.
- Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system. Loosen the fuel fill hose clamp. Disconnect the fuel fill hose from the fuel fill pipe. See Fig 1. Disconnect the rear Evaporative (EVAP) emission pipe at the EVAP canister.
- With the aid of an assistant, support the fuel tank. Remove the attaching bolts (1) from the fuel tank strap. Remove the fuel tank straps (2). Carefully lower the fuel tank. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender. See REMOVAL & INSTALLATION (PLASTIC COLLAR) in QUICK CONNECT FITTINGS. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor. Remove the fuel tank.
- Place the fuel tank in a suitable work area. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination. Remove the EVAP pipe from the roll over valves and the retainer clips. Remove the fuel sender assembly from the fuel tank. See FUEL SENDER ASSEMBLY . Remove the fuel fill hose from the fuel tank.
- To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Inspect for leaks. Turn ignition on for 2 seconds. Turn ignition off for 10 seconds. Turn ignition on. Inspect for fuel leaks.
WARNING:
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.