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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 947 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (1500 Crew Cab) >> 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.
  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 fuel tank shield bolts and shield, if necessary.
    5. Fig 1: Fuel Tank Shield & Bolts (1500 Crew Cab)
    GM1501882Courtesy of GENERAL MOTORS CORP.
  5. 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) .
    6. Fig 2: EVAP Canister & Bolts
    GM1223729Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel feed line from the tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  7. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  8. Place an adjustable jack under the fuel tank.
  9. Remove the fuel tank strap bolts.
  10. Remove the fuel tank straps.
    11. Fig 3: Fuel Tank, Strap & Bolts (1500 Crew Cab)
    GM1223718Courtesy of GENERAL MOTORS CORP.
  11. Remove the harness clip from the frame.
  12. Lower the fuel tank under the electrical connectors are accessible.
  13. Disconnect the fuel tank pressure sensor (1) electrical connector.
  14. Disconnect the fuel tank sending unit (2) electrical connector, perform the following:
    1. Disengage the gray retainer.
    2. Push down the black clip.
    3. Disconnect the connector.
    15. Fig 4: Fuel Tank Pressure Sensor & Fuel Tank Sending Unit
    GM1223770Courtesy 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, 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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