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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Control System - 4.3L - Introduction) >> Repair Instructions >> Fuel Tank Replacement (Cutaway Van Rear Tank) >> Removal Procedure

Removal Procedure

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    Fig 1: View Of Fuel Fill Hose (Cutaway Van Rear Tank)
    GM34268Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  4. Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Loosen the fuel fill hose clamp (2).
  6. Disconnect the fuel fill hose from the fuel tank (1).
    7. Fig 2: Locating Fuel Pipe Connections
    GM420630Courtesy of GENERAL MOTORS CORP.
  7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  8. Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
    10. Fig 3: View Of Fuel Tank (Cutaway Van Rear Tank)
    GM34272Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove the attaching bolts (4) from the fuel tank strap.
  12. Remove the fuel tank straps (3).
  13. Carefully lower the fuel tank.
  14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank. Refer to Fuel Sender Assembly Replacement .
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