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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1025 (Engine Controls And Fuel - 4.3L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (Extended Cab w/26 Gal Tank) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2008 GMC Sierra and 2008 Chevrolet 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: Fuel Tank Shield & Bolts (1500 Crew Cab)
    GM1501882Courtesy 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 Filler Tube Replacement (Regular Cab w/26 Gal Tank)  or Filler Tube Replacement (Extended Cab w/26 Gal Tank)  or Filler Tube Replacement (Regular Cab w/34 Gal Tank) .
  4. Remove the fuel tank shield bolts, if equipped.
    5. Fig 2: Fuel Tank Shield
    GM1853724Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
    6. Fig 3: Quick Connect Fittings
    GM1854683Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel tank EVAP line quick connect fitting (3) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
    9. Fig 4: View Of Fuel Tank & Straps
    GM1854455Courtesy 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. IMPORTANT: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
  12. Lower the fuel tank half way.
  13. Disconnect the chassis wiring harness clip at the frame crossmember.
  14. Lower the fuel tank until the electrical connections are accessible.
    15. Fig 5: Chassis Wiring Harness Electrical Connector At Fuel Tank Pressure Sensor & Fuel Tank Module
    GM1854685Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
  16. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
    20. Fig 6: Fuel Tank Shield & Push On Retainers
    GM1854687Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel tank shield push on retainers.
  21. Remove the fuel tank shield.
    22. Fig 7: Fuel Tank Clips
    GM1854688Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  23. Remove the fuel feed pipe from the fuel tank clips (1).
    24. Fig 8: EVAP Pipe Quick Connect Fitting
    GM1854689Courtesy of GENERAL MOTORS CORP.
  24. Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  25. Remove the EVAP pipe from the fuel tank clips (1).
    26. Fig 9: Fuel Tank Clips
    GM1854690Courtesy of GENERAL MOTORS CORP.
  26. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  27. Remove the EVAP pipe from the fuel tank clips (1 and 2).
  28. Remove the fuel tank module. Refer to Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank)  or Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank)  or Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) .
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