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Home >> GMC >> 2006 >> Sierra 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 878 (Engine Controls And Fuel - 4.8L, 5.3L, 6.0L And 6.2L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2007 GMC Sierra, 2007 GMC Cab & Chassis Sierra, 2007 Chevrolet Silverado, and 2007 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.
    Fig 1: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) or Fuel Pressure Relief (Without CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the fuel tank fill pipe. Refer to Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
  4. Remove the fuel tank shield bolts, if equipped.
    5. Fig 2: Fuel Tank & Shield
    GM1854937Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
    6. Fig 3: Fittings At Fuel Tank
    GM1854924Courtesy of GENERAL MOTORS CORP.
  6. Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
  7. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
  10. Remove the chassis wiring harness clip from the fuel tank shield.
    11. Fig 4: EVAP Canister Vent Solenoid Retainer
    GM1855688Courtesy of GENERAL MOTORS CORP.
  11. Disengage the retainer (1) securing the EVAP canister vent solenoid.
  12. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
    13. Fig 5: Quick Connect Fittings
    GM1854925Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Disconnect the fuel tank EVAP line quick connect fitting (2) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  15. Cap the fuel and EVAP lines in order to prevent possible system contamination.
    16. Fig 6: View Of Fuel Tank And Straps
    GM1854455Courtesy of GENERAL MOTORS CORP.
  16. Place a suitable adjustable jack under the fuel tank.
  17. Remove the fuel tank strap bolts.
  18. Remove the fuel tank straps.
    19. IMPORTANT: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
  19. Lower the fuel tank half way.
  20. Disconnect the chassis wiring harness clip at the frame crossmember.
  21. Lower the fuel tank until the electrical connections are accessible.
    22. Fig 7: Chassis Wiring Harness Electrical Connector At Fuel Tank Pressure Sensor And Fuel Tank Module
    GM1854941Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the chassis wiring harness electrical connector (1) from the fuel tank pressure sensor.
  23. Disconnect the chassis wiring harness electrical connector (2) from the fuel tank module.
  24. Completely lower the fuel tank.
  25. With the aid of an assistant, place the fuel tank in a suitable work area.
  26. If replacing the fuel tank proceed to the next step, otherwise proceed to step 9 in the installation procedure.
    27. Fig 8: Fuel Tank Shield And Push On Retainers
    GM1854926Courtesy of GENERAL MOTORS CORP.
  27. Remove the fuel tank shield push on retainers.
  28. Remove the fuel tank shield.
    29. Fig 9: Fuel Feed Pipe Quick Connect Fitting And Fuel Tank Clips
    GM1854927Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  30. Remove the fuel feed pipe from the fuel tank clips (1).
    31. Fig 10: EVAP Pipe And Fuel Tank Clips
    GM1854928Courtesy of GENERAL MOTORS CORP.
  31. Remove the EVAP pipe from the fuel tank clips (1).
    32. Fig 11: Fuel Tank Clips
    GM1854930Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  33. Remove the EVAP pipe from the fuel tank clips (1).
  34. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
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