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Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Clean all the fuel feed/return and evaporative emission (EVAP) pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel/EVAP system contamination.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Remove the fuel tank filler housing to body screws (1) and retainer (2).
    4. Fig 1: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  4. Remove the fuel tank filler housing to fuel tank fill pipe screws.
  5. Remove the fuel tank filler housing.
    6. Fig 2: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  6. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
    7. Fig 3: View Of Rear Axle Vent Hose
    GM816707Courtesy of GENERAL MOTORS CORP.
  7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Remove the fuel tank ground strap bolt (3).
  9. Remove the chassis harness ground strap (2) and fuel tank ground strap (4).
    10. Fig 4: View Of EVAP Canister Vent Valve Electrical Connector, Chassis Harness Ground Strap, Fuel Tank Ground Strap Bolt & Fuel Tank Ground Strap
    GM815635Courtesy of GENERAL MOTORS CORP.
  10. Loosen the fuel tank fill pipe clamp at the tank.
  11. Remove the fuel tank fill pipe from the tank and vehicle.
    12. Fig 5: View Of Fuel Tank Fill Pipe
    GM816694Courtesy of GENERAL MOTORS CORP.
  12. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  13. If necessary, remove the fuel tank shield bolts.
  14. Remove the fuel tank shield.
    15. Fig 6: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  15. Remove the fuel feed/return pipes from the clip on the fuel tank.
    16. Fig 7: View Of Fuel Feed/Return Pipes At Fuel Tank
    GM878130Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel feed/return pipes from the fuel tank pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  17. Cap the fuel and EVAP pipes in order to prevent possible fuel/EVAP system contamination.
  18. Place a suitable adjustable jack under the fuel tank.
  19. Remove the fuel tank strap bolts.
    NOTE: Refer to Fuel Tank Strap Fastener Notice in Cautions and Notices.
  20. Remove the fuel tank straps.
  21. Lower the fuel tank until the electrical connections are accessible.
    22. Fig 8: View Of Fuel Tank & Straps
    GM300138Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the fuel sending unit and pressure sensor electrical connectors (1).
    23. Fig 9: View Of Pressure Sensor Electrical Connectors
    GM878152Courtesy of GENERAL MOTORS CORP.
  23. Completely lower the fuel tank.
  24. With the aid of an assistant, place the fuel tank in a suitable work area.
  25. Disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
  26. Disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
    27. Fig 10: View Of EVAP Pipe, Fuel Feed & Return
    GM815641Courtesy of GENERAL MOTORS CORP.
  27. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .
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