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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 (Pickup) >> 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.
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 (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 EVAP canister vent solenoid. Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis) .
  5. Remove the fuel tank shield bolts, if equipped.
  6. Remove the fuel tank shield, if equipped.
    7. Fig 1: Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed and EVAP lines. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
    9. Fig 2: Fuel And EVAP Lines At The Fuel Tank
    GM1238591Courtesy of GENERAL MOTORS CORP.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
    12. Fig 3: Fuel Tank, Strap & Bolts (Pickup)
    GM1228093Courtesy of GENERAL MOTORS CORP.
  12. Lower the fuel tank half way.

    When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.

  13. Disconnect the electrical harness clip at the frame crossmember.
  14. Lower the fuel tank until the electrical connections are accessible.
  15. Disconnect the fuel pressure sensor electrical connector.
    16. Fig 4: Fuel Pressure Sensor Electrical Connector
    GM1238148Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel sending unit electrical connector, perform the following:
    1. Disengage the gray retainer.
    2. Push down the black clip.
    3. Disconnect the connector.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
  20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
  21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
    22. Fig 5: Fuel Feed Line, EVAP Purge Line & FLVV Line
    GM1306291Courtesy of GENERAL MOTORS CORP.
  22. 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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