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Fuel Tank: Removal

WARNING: Do not allow smoking or the use of open flame in the area where work on the fuel system is taking place.
  1. Ensure that fuel level in tank is less than 1/4 full. If necessary, drain fuel tank to at least this level. Refer to FUEL TANK DRAINING  .
    WARNING: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
  2. Position vehicle on hoist.
    CAUTION: Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
  3. Disconnect negative battery cable.
    NOTE: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.
  4. Relieve fuel system pressure. See Figure . Refer to FUEL SYSTEM PRESSURE RELIEF  .
  5. Raise vehicle to a comfortable working position.
  6. Remove exhaust system intermediate pipe (with muffler).
    Fig 1: Removing Exhaust System Intermediate Pipe
    G01019392Courtesy of GENERAL MOTORS CORP.
  7. Remove rear heat shield retaining bolts.
    Fig 2: Removing Rear Heat Shield Retaining Bolts
    G01019393Courtesy of GENERAL MOTORS CORP.
  8. Remove fuel filler pipe lower bracket attachment screw. See Figure .
    CAUTION: Whenever fuel lines are removed, place fuel in an approved container. Container opening must be a minimum of 300 mm (12 in.) diameter to adequately catch fuel.
  9. Disconnect EVAP canister vent hose.
    Fig 3: Disconnecting EVAP Canister Vent Hose
    G01019395Courtesy of GENERAL MOTORS CORP.
  10. Loosen fuel filler pipe hose clamp closest to fuel tank.
  11. Disconnect quick connect at recirculation line.
    NOTE: If there is more than three gallons of fuel in the tank, insert a suitable siphon hose into tank filler neck and remove remaining fuel into a certified fuel handling cart.
  12. Disengage filler pipe hose from fuel tank.
  13. Remove tank grounding strap attachment nut located near the fuel filter.
  14. Remove fuel tank strap bracket (fuel line stone chip guard) protecting fuel line connections between fuel tank and chassis fuel bundle. See Figure .
    CAUTION: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.
  15. Disconnect fuel feed line after fuel filter.
  16. Disconnect fuel return and EVAP canister purge lines between tank and chassis fuel bundle.
  17. Disconnect fuel tank electrical connections.
  18. Loosen front tank strap bolts, but do not remove.
  19. With aid of an assistant, remove the two rear tank retaining strap bolts.
    1. Lower rear half of tank and slide the fuel tank down and out rearward.
    2. Remove fuel tank from vehicle.
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