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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> 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 (25 Ext/Crew Cab w/26 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: Fuel Tank Fuel Feed And EVAP Line Quick Connect Fittings
    GM1854337Courtesy 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. Disconnect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings from the chassis lines. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Cap the fuel and EVAP lines in order to prevent possible system contamination.
    6. Fig 2: Solenoid Pipe Clip, Canister Pipe Quick Connect Fitting & Canister Vent Solenoid Pipe Quick Connect Fitting
    GM1854542Courtesy 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 3: Canister Vent Solenoid Retainer
    GM1854543Courtesy of GENERAL MOTORS CORP.
  11. Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1).
  12. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
  13. Position and secure the EVAP canister vent solenoid out of the way.
    14. Fig 4: View Of Fuel Tank And Straps
    GM1854455Courtesy of GENERAL MOTORS CORP.
  14. Place a suitable adjustable jack under the fuel tank.
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.
    17. IMPORTANT: When lowering the tank, ensure that the fill neck on the tank does not get hung up on the chassis wiring harness.
  17. Lower the fuel tank half way.
  18. Disconnect the chassis wiring harness clip at the frame crossmember.
  19. Lower the fuel tank until the electrical connections are accessible.
    20. Fig 5: Chassis Wiring Harness Electrical Connector From The Fuel Tank Pressure Sensor And Fule Tank Module
    GM1854422Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
  21. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
  22. Completely lower the fuel tank.
  23. With the aid of an assistant, place the fuel tank in a suitable work area.
  24. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
    25. Fig 6: Fuel Tank Shield And Push On Retainers
    GM1854481Courtesy of GENERAL MOTORS CORP.
  25. Remove the fuel tank shield push on retainers.
  26. Remove the fuel tank shield.
    27. Fig 7: Fuel Feed Pipe Quick Connect Fitting
    GM1854498Courtesy of GENERAL MOTORS CORP.
  27. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  28. Remove the fuel feed pipe from the fuel tank clip (1).
    29. Fig 8: Locating Fuel Tank Clip
    GM1854507Courtesy of GENERAL MOTORS CORP.
  29. Remove the EVAP canister purge pipe from the fuel tank clip (1).
    30. Fig 9: Locating Fuel Tank Clips
    GM1854508Courtesy of GENERAL MOTORS CORP.
  30. Disconnect the EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  31. Remove the EVAP rear pipe from the fuel tank clips (1 and 2).
    32. Fig 10: Small EVAP Rear Pipe Quick Connect Fittings
    GM1854510Courtesy of GENERAL MOTORS CORP.
  32. Disconnect the small EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  33. 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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