GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Chevy K Silverado - 4WD 🢒 Engine 🢒 Engine Controls - 8.1L 🢒 Fuel Tank Replacement

Fuel Tank Replacement Front Tank

Removal Procedure

    Object Number: 569589 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .

    5. Object Number: 625803 Size: SH
  5. Disconnect the EVAP vent pipe (3) at the fuel tank clip (5).

    6. Object Number: 569669 Size: SH
  6. Loosen the vent hose clamp (7).
  7. Disconnect the vent hose (6) from the fuel tank.

    8. Object Number: 570570 Size: SH
  8. Disconnect the fuel fill hose (2) from the fuel tank.

    9. Object Number: 570588 Size: SH
  9. With the aid of an assistant, support the fuel tank.
  10. Remove the fuel tank strap attaching bolts.
  11. Remove the fuel tank straps.
  12. Carefully lower the rear of the fuel tank slightly.
  13. Remove the fuel sender cover, on the suburban only.

    14. Object Number: 569633 Size: SH
  14. Disconnect the fuel feed, return, and evaporative emission (EVAP) pipes (1, 2, 3) at the fuel sender.
  15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.

    18. Object Number: 570582 Size: SH
  18. Disconnect the EVAP pipe from the fuel tank roll over valves (2, 4) and the retaining clips (1).
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

Installation Procedure

    Object Number: 570582 Size: SH
  1. Connect the EVAP pipe to the fuel tank roll over valves (2, 4) and the retaining clips (1).
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

    3. Object Number: 569633 Size: SH
  3. With the aid of an assistant, support and partially raise the fuel tank front end first.
  4. Connect the fuel sender and the fuel pressure sensor electrical connectors.
  5. Connect the fuel feed, return, and EVAP pipes (1, 2, 3) at the fuel sender.
  6. Install the fuel sender cover, on the suburban only.

    7. Object Number: 570588 Size: SH
  7. Fully raise the fuel tank.
  8. Install the fuel tank straps.

    9. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  9. Install the fuel tank strap bolts.

    10. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 569669 Size: SH
  10. Connect the vent hose (6) to the fuel tank.

    11. Tighten
    Tighten the vent hose clamp (7) to 2.5 N·m (22 lb in)


    Object Number: 570570 Size: SH
  11. Connect the fuel fill hose (2) to the fuel tank.

    12. Tighten
    Tighten the fuel fill hose clamp (1) to 2.5 N·m (22 lb in)


    Object Number: 625803 Size: SH
  12. Connect the EVAP vent pipe to the fuel tank clip (5).

    13. Object Number: 569589 Size: SH
  13. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  14. Lower the vehicle.
  15. Refill the fuel tank.
  16. Install the fuel filler cap.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  18. Inspect for leaks using the following procedure:
    19. 18.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    18.2. Turn OFF the ignition for 10 seconds.
    18.3. Turn ON the ignition, with the engine OFF.
    18.4. Inspect for fuel leaks.
  19. Install the engine sight shield.

Fuel Tank Replacement Rear Tank

Removal Procedure
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Lower and remove the under chassis mounted spare tire.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the rear exhaust hanger bolts and hanger.
  5. Remove the rear crossmember that holds the spare tire.
  6. Drain the fuel tank. Refer to Fuel Tank Draining .

    7. Object Number: 853733 Size: SH
  7. Loosen the fuel tank filler hose clamp at the front tank.
  8. Remove the filler hose from the front tank, and reposition the hose towards the rear tank.

    9. Object Number: 853726 Size: SH
  9. Remove the fuel pipe ground strap bolt.
  10. Separate the ground straps (1, 2).

    11. Object Number: 853727 Size: SH
  11. Loosen the fuel tank filler pipe hose clamp at the rear tank.
  12. Separate the filler pipe from the rear tank.

    13. Object Number: 569704 Size: SH
  13. Loosen the vent hose clamp (2) at the vent pipe (1).
  14. Remove the vent hose (3) from the vent pipe (1).
  15. Lower the vehicle.

    16. Object Number: 853731 Size: SH
  16. Remove the fuel tank filler housing to body screws (1) and retainer (2).

    17. Object Number: 300318 Size: SH
  17. Remove the fuel tank filler housing to fuel tank filler pipe screws.
  18. Remove the fuel tank filler housing from the vehicle.
  19. Remove the fuel filler pipe from the vehicle.
  20. Raise the vehicle.
  21. Support the fuel tank with a suitable jack.

    22. Object Number: 570586 Size: SH
  22. Remove the fuel tank strap bolts.
  23. Remove the fuel tank straps.
  24. Partially lower the rear tank.

    25. Object Number: 853732 Size: SH
  25. Loosen the fuel tank filler hose clamp at the rear tank.
  26. Remove the filler hose from the rear tank.

    27. Object Number: 853728 Size: SH
  27. Disconnect the evaporative emission (EVAP) tubes (2) at the EVAP pipes.
  28. Disconnect the fuel pipe at the fuel sender (1). Refer to Metal Collar Quick Connect Fitting Service .
  29. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

    30. Object Number: 853734 Size: SH
  30. Disconnect the fuel tank electrical connector.
  31. Lower the fuel tank.
  32. With the aid of an assistant, remove the tank from the jack.
  33. Remove the fuel sender assembly, if required. Refer to Fuel Sender Assembly Replacement .

    34. Object Number: 570577 Size: SH
  34. Remove the EVAP pipes from the fuel tank roll over valves (1, 3) and the retaining clips (2), if required.

Installation Procedure

    Object Number: 570577 Size: SH
  1. Install the EVAP pipes to the fuel tank roll over valves (1, 3) and the retaining clips (2), if required.
  2. Install the fuel sender assembly, if required. Refer to Fuel Sender Assembly Replacement .
  3. With the aid of an assistant, install the tank to the jack.
  4. Partially raise the fuel tank.

    5. Object Number: 853734 Size: SH
  5. Connect the fuel tank electrical connector.

    6. Object Number: 853728 Size: SH
  6. Remove the caps from the fuel and EVAP pipes.
  7. Connect the fuel pipe at the fuel sender (1).
  8. Connect the EVAP tubes (2) at the EVAP pipes.

    9. Object Number: 853732 Size: SH
  9. Install the filler hose to the rear tank.
  10. Position the hose clamp screw downwards, for easy access.

    11. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  11. Tighten the fuel tank filler hose clamp at the rear tank.

    12. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in).


    Object Number: 570586 Size: SH
  12. Completely raise and install the tank.
  13. Install the fuel tank straps.
  14. Install the fuel tank strap bolts.

    15. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).

  15. Remove the jack from the fuel tank.
  16. Lower the vehicle.

    17. Object Number: 300318 Size: SH
  17. Install the fuel filler pipe to the vehicle.
  18. Install the fuel tank filler housing to the vehicle.
  19. Install the fuel tank filler housing to fuel tank filler pipe screws.

    20. Tighten
    Tighten the screws to 2.3 N·m (20 lb in).


    Object Number: 853731 Size: SH
  20. Install the fuel tank filler housing to body screws (1) and retainer (2).

    21. Tighten
    Tighten the screws to 2.3 N·m (20 lb in).

  21. Raise the vehicle.

    22. Object Number: 569704 Size: SH
  22. Install the vent hose (3) to the vent pipe (1).
  23. Tighten the vent hose clamp (2) at the vent pipe (1).

    24. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in).


    Object Number: 853727 Size: SH
  24. Connect the filler pipe to the rear tank.
  25. Tighten the fuel tank filler pipe hose clamp at the rear tank.

    26. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in).


    Object Number: 853726 Size: SH
  26. Align and position the chassis wiring harness ground strap (2) and fuel filler pipe ground strap (1).
  27. Install the fuel pipe ground strap bolt.

    28. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 853733 Size: SH
  28. Install the filler hose to the front tank.
  29. Tighten the fuel tank filler hose clamp at the front tank.

    30. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in).

  30. Install the rear crossmember that holds the spare tire.
  31. Install the rear exhaust hanger bolts and hanger.
  32. Lower the vehicle.
  33. Install and raise the under chassis mounted spare tire.

Fuel Tank Replacement Cab/Chassis Front

Removal Procedure

    Object Number: 667724 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank shield (1).

    5. Object Number: 667876 Size: SH
  5. Disconnect the fuel fill and vent pipe (2) from the fuel tank.

    6. Object Number: 667731 Size: SH
  6. With the aid of an assistant, support the fuel tank.
  7. Remove the fuel tank strap attaching bolts.
  8. Remove the fuel tank straps (1).
  9. Carefully lower the fuel tank slightly.
  10. Disconnect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
  11. Disconnect the fuel sender and the fuel pressure sensor harness connectors.
  12. Remove the fuel tank.
  13. Place the fuel tank in a suitable work area.
  14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  15. Cap the fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.

Installation Procedure

    Object Number: 667731 Size: SH
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, support and partially raise the fuel tank.
  4. Connect the fuel sender and the fuel pressure sensor harness connectors.
  5. Connect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
  6. Fully raise the fuel tank (2).
  7. Install the fuel tank straps (1).

    8. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the fuel tank strap bolts.

    9. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 667876 Size: SH
  9. Connect the fuel fill and vent pipe (2) to the fuel tank.

    10. Tighten
    Tighten the hose clamps to 2.5 N·m (22 lb in).


    Object Number: 667724 Size: SH
  10. Install the fuel tank shield (1).
  11. Lower the vehicle.
  12. Refill the fuel tank (2).
  13. Install the fuel filler cap.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Inspect for leaks using the following procedure:
    16. 15.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition with the engine OFF.
    15.4. Inspect for fuel leaks.
  16. Install the engine sight shield.

Fuel Tank Replacement Cab/Chassis Rear

Removal Procedure

    Object Number: 667863 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank shield (2).

    5. Object Number: 667878 Size: SH
  5. Disconnect the fuel fill and vent pipe (1) from the fuel tank.

    6. Object Number: 667869 Size: SH
  6. With the aid of an assistant, support the fuel tank.
  7. Remove the fuel tank strap attaching bolts (2).
  8. Remove the fuel tank straps (3).
  9. Carefully lower the fuel tank slightly.
  10. Disconnect the fuel and evaporative emission (EVAP) pipes. Refer to Metal Collar Quick Connect Fitting Service .
  11. Disconnect the fuel sender and the fuel pressure sensor harness connectors.
  12. Remove the fuel tank.
  13. Place the fuel tank in a suitable work area.
  14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  15. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

Installation Procedure

    Object Number: 667869 Size: SH
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, support and partially raise the fuel tank.
  4. Connect the fuel sender and the fuel pressure sensor harness connectors.
  5. Connect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
  6. Fully raise the fuel tank.
  7. Install the fuel tank straps (3).

    8. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the fuel tank strap bolts (2).

    9. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 667878 Size: SH
  9. Connect the fuel fill and vent pipe (1) to the fuel tank.

    10. Tighten
    Tighten the fuel fill hose clamps to 2.5 N·m (22 lb in).


    Object Number: 667863 Size: SH
  10. Install the fuel tank shield (2).
  11. Lower the vehicle.
  12. Refill the fuel tank.
  13. Install the fuel filler cap.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Inspect for leaks using the following procedure:
    16. 15.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition, with the engine OFF.
    15.4. Inspect for fuel leaks.
  16. Install the fuel injection sight shield.

Fuel Tank Replacement Pickup

Removal Procedure

    Object Number: 300318 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Disconnect the fuel fill pipe from the fuel fill pipe housing.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 420291 Size: SH
  5. Disconnect the fuel fill pipe ground strap.

    6. Object Number: 303981 Size: SH
  6. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .

    7. Object Number: 303903 Size: SH
  7. Disconnect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

    9. Object Number: 373155 Size: SH
  9. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.

    10. Object Number: 626413 Size: SH
  10. Remove the fuel tank shield.

    11. Object Number: 300138 Size: SH
  11. With the aid of an assistant, support the fuel tank.
  12. Remove the fuel tank strap attaching bolts.
  13. Remove the fuel tank straps.
  14. Remove the fuel tank.
  15. Place the fuel tank in a suitable work area.

    16. Object Number: 396067 Size: SH
  16. Remove the fuel feed pipe (4) and the fuel return pipe (5) from the fuel sender (2) and the retaining clips (6).
  17. Remove the EVAP pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
  18. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  19. Remove the fuel fill and vent hose and pipe assembly from the fuel tank.

Installation Procedure
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the fuel fill and vent hose and pipe assembly to the fuel tank.

    3. Tighten
    Tighten the hose clamp to 2.5 N·m (22 lb in).


    Object Number: 396067 Size: SH
  3. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
  4. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender and the retaining clips.

    5. Object Number: 300138 Size: SH
  5. With the aid of an assistant, position and support the fuel tank.
  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts.

    8. Tighten
    Tighten the bolts to 40 N·m (30 lb ft).


    Object Number: 626414 Size: SH
  8. Install the fuel tank shield to the fuel tank clips.

    9. Object Number: 626413 Size: SH
  9. Install the fuel tank shield to frame bolts.

    10. Tighten
    Tighten the bolts to 18 N·m (13 lb ft).


    Object Number: 373155 Size: SH
  10. Connect the fuel sender and the fuel pressure sensor electrical connectors.

    11. Object Number: 303903 Size: SH
  11. Remove the caps from the fuel and EVAP pipes.
  12. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .

    13. Object Number: 303981 Size: SH
  13. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .

    14. Object Number: 420291 Size: SH
  14. Connect the fuel fill pipe ground strap.

    15. Tighten
    Tighten the fuel fill pipe ground strap bolt to 9 N·m (80 lb in).

  15. Lower the vehicle.

    16. Object Number: 300318 Size: SH
  16. Connect the fuel fill pipe to the fuel fill pipe housing.

    17. Tighten
    Tighten the fuel fill pipe housing screws to 2.3 N·m (20 lb in).

  17. Refill the fuel tank.
  18. Install the fuel filler cap.
  19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  20. Inspect for leaks using the following procedure:
    21. 20.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    20.2. Turn OFF the ignition for 10 seconds.
    20.3. Turn ON the ignition, with the engine OFF.
    20.4. Inspect for fuel leaks.
  21. Install the engine sight shield.