Fuel Tank Replacement (2-Door Utility): Notes

Removal Procedure

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure (2-Door Utility) .
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the left rear splash shield.
Fig 1: Locating Fuel Fill Hose Clamp & Vent Hose Clamp
Courtesy of GENERAL MOTORS CORP.
5. Loosen the fuel fill hose clamp (2) and the vent hose clamp (1) at the fuel tank.
6. Disconnect the fuel fill hose and the vent hose from the fuel tank.
Fig 2: View Of Fuel Tank Shield
Courtesy of GENERAL MOTORS CORP.
7. Remove the fuel tank shield.
8. Support the fuel tank.
Fig 3: Locating Fuel Tank Straps
Courtesy of GENERAL MOTORS CORP.
9. Remove the fuel tank straps.
NOTE: Use extreme care when lowering the fuel tank. The fuel sender is made of plastic. Lowering the fuel tank may damage the fuel sender.
10. Lower the fuel tank.
Fig 4: View Of Fuel Sender Assembly
Courtesy of GENERAL MOTORS CORP.
11. Disconnect the fuel pressure sensor and the fuel sender electrical connectors.
12. Disconnect the fuel feed pipe, the fuel return pipe, and the evaporative emission (EVAP) pipe at the fuel sender.
13. Remove the fuel tank from the vehicle.
Fig 5: View Of Fuel Sender
Courtesy of GENERAL MOTORS CORP.
14. Remove the fuel sender from the fuel tank. Refer to Fuel Sender Assembly Replacement (Utility/Crew Cab)  or Fuel Sender Assembly Replacement (Pick-Up) .