Removal & Installation (Passenger/Cargo Van)
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.
CAUTION:
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
NOTE:
Numbers in parenthesis refer to numbers in illustrations.
- Disconnect the negative battery cable. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank. Raise the vehicle.
- Disconnect the fuel fill hose from the fuel fill pipe. See Fig 1. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Disconnect the chassis fuel feed pipe at the fuel filter. Disconnect the chassis Evaporative (EVAP) emission purge pipe at the EVAP canister. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
- With the aid of an assistant, support the fuel tank. Remove the attaching bolts (1) from the fuel tank strap. See Fig 2. Remove the fuel tank straps (2). Carefully lower the fuel tank. Disconnect the fuel sender and the fuel pressure sensor electrical connectors. Remove the fuel tank. Place the fuel tank in a suitable work area.
- Disconnect the EVAP pipe at the front roll-over valve (1), the rear roll-over valve (2), the EVAP canister (3), and the retainer clips. See Fig 3. Remove the fuel sender assembly and the fuel pipes (4) from the fuel tank and the fuel filter. Remove the fuel fill hose from the fuel tank. Remove the fuel tank from the fuel tank shield.
- 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.