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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System - 4.8L, 5.3L & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Single Tank w/5.3L (L59) Engine) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
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 (Single Tank)  or Fuel Tank Draining Procedure (5.3L (L59) Engine)  or Fuel Tank Draining Procedure (Dual Tanks - Front)  or Fuel Tank Draining Procedure (Dual Tanks - Rear) .
  3. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission (EVAP) Canister Replacement (1500 Series)  or Evaporative Emission (EVAP) Canister Replacement (1500 Series - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Replacement (2500 Series) .
  4. Loosen the vent hose clamp.
  5. Remove the vent hose from the fuel tank.
    6. Fig 1: View Of Chassis Fuel Pipe & Fuel Tank Pipe
    GM855745Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the chassis fuel pipe (4) from the fuel tank pipe (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Using J 43178  , disconnect the chassis fuel pipe (4) from the fuel tank pipe (3). See Special Tools and Equipment .
  8. Cap the fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
    9. Fig 2: View Of EVAP Canister Vent Pipe & Clips
    GM855747Courtesy of GENERAL MOTORS CORP.
  9. Using an adjustable jack, support the fuel tank.
  10. Lower the fuel tank slightly.
  11. Disconnect the EVAP vent pipe from the fuel tank clips (6, 7).
    12. Fig 3: View Of Fuel Tank & Straps (Single Tank w/5.3L (L59) Engine)
    GM855751Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Damage to Fuel Tank Straps Notice in Cautions and Notices.
  12. Remove the fuel tank strap bolts.
  13. Remove the fuel tank straps.
  14. With the aid of an assistant, carefully lower the rear of the fuel tank.
  15. Slide the front of the tank away from the frame.
    16. Fig 4: View Of Sending Unit Shield
    GM858234Courtesy of GENERAL MOTORS CORP.
  16. If equipped, remove the sending unit shield nuts.
  17. If equipped, remove the sending unit shield.
    18. Fig 5: View Of Fuel Sender & Fuel Pressure Sensor Electrical Connectors (Single Tank w/5.3L (L59) Engine)
    GM855750Courtesy of GENERAL MOTORS CORP.
  18. Release the connector position assurance (CPA) retainer.
  19. Disconnect the fuel sender and fuel pressure sensor electrical connectors (2).
  20. Completely lower the fuel tank.
  21. Place the fuel tank in a suitable work area.
  22. Remove the fuel feed and return pipes from the fuel sending unit and the retaining clips.
  23. If necessary, remove the fuel sending unit. Refer to Fuel Sender Assembly Replacement (4.8L and 5.3L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Front)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Rear) .
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