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Home >> GMC >> 2002 >> C3500 HD 8.1 G, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 8.1L >> Repair Instructions >> Fuel Tank Replacement (Side) >> Removal Procedure
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Removal Procedure

  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
  2. Drain the fuel from the tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle.
  4. Disconnect the vent hose at the fuel tank.
    Fig 1: Disconnecting Vent Hose At Fuel Tank
    G01598911Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the filler tube hose at the fuel tank.
    Fig 2: Disconnecting Filler Tube Hose
    G01598912Courtesy of GENERAL MOTORS CORP.
  6. Support the fuel tank.
  7. Remove the fuel tank straps.
    Fig 3: Fuel Tank Straps (Side)
    G01598913Courtesy of GENERAL MOTORS CORP.
  8. With the aid of an assistant lower the fuel tank and shield. Lower the fuel tank shield and the fuel tank to access the top of the fuel tank.
    Fig 4: Fuel Tank & Shield
    G01598914Courtesy of GENERAL MOTORS CORP.
  9. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  10. Disconnect the fuel pipes (1,3) and the vapor pipe (2). Refer to Quick Connect Fitting(s) Service (Metal Collar)  or Quick Connect Fitting(s) Service (Plastic Collar) .
  11. Disconnect the electrical connections at the sender.
  12. Remove the fuel tank and shield.
  13. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement .
    Fig 5: Fuel Pipes & Vapor Pipe
    G01598915Courtesy of GENERAL MOTORS CORP.