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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 973 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Pickup - 5.3L (L59) Engine) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)  or Fuel Tank Draining Procedure (5.3L (L59) Engine) .
  3. Remove the fuel tank fill pipe. Refer to Filler Tube Replacement (Pickup)  or Filler Tube Replacement (Pickup - 5.3L (L59) Engine)  or Filler Tube Replacement (1500 Crew Cab)  or Filler Tube Replacement (Cab/Chassis - Front)  or Filler Tube Replacement (Cab/Chassis - Rear) .
  4. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission (EVAP) Canister Replacement (Pickup)  or Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)  or Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis) .
  5. If equipped, remove the fuel tank shield bolts.
  6. If equipped, remove the fuel tank shield.
    7. Fig 1: Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed and return line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    8. Fig 2: Fuel Feed And Return Line Quick Connect Fittings
    GM878130Courtesy of GENERAL MOTORS CORP.
  8. Cap the fuel lines in order to avoid possible system contamination.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
    12. Fig 3: Fuel Tank, Strap & Bolts (Pickup - 5.3L (L59))
    GM300138Courtesy of GENERAL MOTORS CORP.
  12. Lower the fuel tank until the electrical connections are accessible.
  13. Remove the fuel sending unit connector position assurance (CPA) retainer.
  14. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors (1).
    15. Fig 4: Fuel Pressure Sensor Electrical Connectors (Pickup - 5.3L (L59))
    GM878152Courtesy of GENERAL MOTORS CORP.
  15. Completely lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
  18. If necessary, disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
    19. Fig 5: EVAP Pipe, Fuel Feed And Return Pipes
    GM815641Courtesy of GENERAL MOTORS CORP.
  19. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine) .
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