GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Colorado Pickup - 2WD 🢒 Engine 🢒 Engine Controls - 3.5L (L52) 🢒 Fuel Tank Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle, high enough to access the top of the fuel tank through the wheelhouse liner. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the left pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement in Body Rear End.

    5. Object Number: 1361710 Size: SH
  5. Disconnect the fuel filler hose (4) from the fuel tank (3).
  6. Disconnect the evaporative emission (EVAP) hose (2) from the filler vent tube (1). Refer to Plastic Collar Quick Connect Fitting Service .

    7. Object Number: 1361711 Size: SH
  7. Disconnect the following electrical connectors from the fuel tank:
    8. • The fuel tank pressure sensor (2)
    • The fuel tank module (3)
  8. Disengage the fuel wiring harness from the retainer (5) on the fuel tank.
  9. Raise the vehicle fully.

    10. Object Number: 1361712 Size: SH
  10. Disconnect the middle of the EVAP vapor pipe (1, 3) located between the fuel tank and the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .

    11. Object Number: 1361713 Size: SH
  11. Refer to Plastic Collar Quick Connect Fitting Service in order to disconnect the following from the chassis bundle (2, 3):
    12. • The fuel return hose (1)
    • The fuel filter (4)

    Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.


    Object Number: 1361714 Size: SH
  12. Remove the upper fuel tank strap bolt.
  13. Remove the upper fuel tank strap.
  14. Support the fuel tank.

    15. Object Number: 1361715 Size: SH
  15. Remove the lower fuel tank strap bolt.
  16. Remove the lower fuel tank strap.
  17. With the aid of an assistant, carefully lower the fuel tank from the vehicle.
  18. Place the fuel tank in a suitable work area.
  19. If the fuel tank is not being replaced, go to the Installation Procedure.

Disassembly Procedure
  1. Remove the fuel filter. Refer to Fuel Filter Replacement .

    2. Object Number: 1361716 Size: SH
  2. Refer to Plastic Collar Quick Connect Fitting Service in order to disconnect the following from the fuel tank module (2):
    3. • The EVAP pipe (5)
    • The fuel return pipe (6)
    • The fuel feed pipe (7)
  3. Disconnect the EVAP pipes (3, 5) from the vent valve (4). Refer to Plastic Collar Quick Connect Fitting Service .
  4. Disengage the following from the retaining clips (1):
    5. • The fuel return pipe (6)
    • The fuel feed pipe (7)
  5. Disengage the EVAP pipe (5) from the retaining features molded into the fuel tank.
  6. Remove the fuel tank module from the fuel tank. Refer to Fuel Tank Module Replacement .

Assembly Procedure
  1. Install the fuel tank module into the fuel tank. Refer to Fuel Tank Module Replacement .

    2. Object Number: 1361716 Size: SH
  2. Secure the EVAP pipe (5) to the retaining features molded into the fuel tank.
  3. Secure the following to the retaining clips (1):
    4. • The fuel return pipe (6)
    • The fuel feed pipe (7)
  4. Connect the EVAP pipes (3, 5) to the vent valve (4). Refer to Plastic Collar Quick Connect Fitting Service .
  5. Refer to Plastic Collar Quick Connect Fitting Service in order to connect the following to the fuel tank module (2):
    6. • The EVAP pipe (5)
    • The fuel return pipe (6)
    • The fuel feed pipe (7)
  6. Install the fuel filter. Refer to Fuel Filter Replacement .

Installation Procedure

    Object Number: 1361715 Size: SH
  1. With the aid of an assistant, carefully position and support the fuel tank to the vehicle.
  2. Install the lower fuel tank strap.
  3. Install the lower fuel tank strap bolt.

    4. Do not tighten at this time.


    Object Number: 1361714 Size: SH
  4. Install the upper fuel tank strap.

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the upper fuel tank strap bolt.

    6. Tighten
    Tighten the fuel tank strap bolts to 32 N·m (24 lb ft).


    Object Number: 1361713 Size: SH
  6. Refer to Plastic Collar Quick Connect Fitting Service in order to connect the following to the chassis bundle (2, 3):
    7. • The fuel return hose (1)
    • The fuel filter (4)

    Object Number: 1361712 Size: SH
  7. Connect the middle of the EVAP vapor pipe (1, 3) located between the fuel tank and the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Lower the vehicle only enough to gain access the fuel tank through the wheelhouse.

    9. Object Number: 1361711 Size: SH
  9. Connect the following electrical connectors to the fuel tank:
    10. • The fuel tank pressure sensor (2)
    • The fuel tank module (3)
  10. Secure the fuel tank wiring harness to the retainer (5) on the fuel tank.

    11. Object Number: 1361710 Size: SH
  11. Connect the fuel filler hose (4) to the fuel tank (3).

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

  12. Connect the EVAP hose (2) to the filler vent tube (1). Refer to Plastic Collar Quick Connect Fitting Service .
  13. Install the left pickup box wheelhouse liner. Refer to Pickup Box Wheelhouse Liner Replacement in Body Rear End.
  14. Lower the vehicle.
  15. Refill the fuel tank.
  16. Install the fuel filler cap.
  17. Inspect for leaks.
    18. 17.1. Turn ON the ignition, with the engine OFF for 10 seconds.
    17.2. Turn OFF the ignition for 10 seconds.
    17.3. Turn ON the ignition, with the engine OFF.
    17.4. Inspect for fuel leaks.