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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 Side Tank) >> Removal Procedure

Removal Procedure

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    Fig 1: View Of Fuel Tank Fill Pipe
    GM1198967Courtesy 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. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  6. Loosen the fuel fill hose clamp.
  7. Disconnect the fuel fill hose from the fuel fill pipe.
  8. Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.
    9. Fig 2: View Of Fuel Tank (Cutaway Van Side Tank)
    GM601673Courtesy of GENERAL MOTORS CORP.
  9. With the aid of an assistant, support the fuel tank.
  10. Remove the attaching bolts (1) from the fuel tank strap.
  11. Remove the fuel tank straps (2).
  12. Carefully lower the fuel tank.
  13. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  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. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
  18. Remove the EVAP pipe from the roll over valves and the retainer clips.
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Remove the fuel fill hose from the fuel tank.
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