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Home >> Chevrolet >> 2004 >> Suburban C2500, 8.1 G >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 8.1L (Introduction) >> Repair Instructions >> Fuel Tank Replacement (Front Tank) >> Removal Procedure

Removal Procedure

IMPORTANT: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.
    Fig 1: View Of Fuel Fill Hose
    GM1224382Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Front Tank)  or Fuel Tank Draining Procedure (Rear Tank) .
  3. Disconnect the EVAP vent line from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    4. Fig 2: View Of Vapor Line At Fuel Tank
    GM1372488Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the vapor line (1) from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    5. Fig 3: View Of Fuel Feed & EVAP Lines At Fuel Tank
    GM1372476Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the fuel feed and EVAP lines from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  6. Open the clip on the side of the fuel tank retaining the intermediate lines.
  7. Disconnect the fuel and EVAP intermediate lines from the front tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  8. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.
    9. Fig 5: View Of Fuel Tank Shield (Front Tank)
    GM856641Courtesy of GENERAL MOTORS CORP.
  9. If equipped, remove the fuel tank shield bolts.
  10. If equipped, remove the fuel tank shield.
    11. Fig 6: View Of Fuel Tank & Straps (Front Tank)
    GM1224378Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Damage to Fuel Tank Straps Notice in Cautions and Notices.
  11. Using an adjustable jack, support the fuel tank.
  12. Remove the fuel tank strap bolts.
  13. Remove the fuel tank straps.
  14. With the aid of an assistant, carefully lower the fuel tank until the sending unit is accessible.
    15. Fig 7: View Of Sending Unit Electrical Connector (Front Tank)
    GM1238171Courtesy of GENERAL MOTORS CORP.
  15. Disengage the connector position assurance (CPA) retainer.
  16. Disconnect the sending unit electrical connector.
  17. Completely lower the fuel tank.
  18. Place the fuel tank in a suitable work area.
  19. If necessary, remove the sending unit. Refer to Fuel Sender Assembly Replacement (Front Tank)  or Fuel Sender Assembly Replacement (Rear Tank) .
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