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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 .
  3. Remove the fuel tank fill pipe. Refer to Filler Tube Replacement (Pickup)  or Filler Tube Replacement (Cab/Chassis - Front)  or Filler Tube Replacement (Cab/Chassis - Rear) .
  4. Disconnect the EVAP canister vent solenoid electrical connector.
    Fig 1: EVAP Canister Vent Solenoid
    GM1228110Courtesy of GENERAL MOTORS CORP.
  5. Remove the EVAP canister vent solenoid from the fuel tank.
    6. Fig 2: Fuel Tank Shield
    GM626413Courtesy of GENERAL MOTORS CORP.
  6. If equipped, remove the fuel tank shield bolts.
  7. Remove the fuel tank shield.
  8. Disconnect the fuel feed and EVAP quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  10. Place a suitable adjustable jack under the fuel tank.
  11. Remove the fuel tank strap bolts.
    Fig 3: Fuel Tank Assembly
    GM1228093Courtesy of GENERAL MOTORS CORP.
  12. Remove the fuel tank straps.
  13. Lower the fuel tank until the electrical connections are accessible.
    14. Fig 4: Fuel Sending Unit And Fuel Pressure Sensor Electrical Connectors - Pickup
    GM1238148Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors.
  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 .
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