GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Tahoe - 2WD 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Fuel Tank Replacement

Fuel Tank Replacement Pickup

Removal Procedure

    Object Number: 300318 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Disconnect the fuel fill pipe from the fuel fill pipe housing.
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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

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

    8. Object Number: 303903 Size: SH
  8. 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 .
  9. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

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

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

    12. Object Number: 300138 Size: SH
  12. With the aid of an assistant, support the fuel tank.

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

  13. Remove the fuel tank strap attaching bolts.
  14. Remove the fuel tank straps.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.

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

    19. Object Number: 386369 Size: MH
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Remove the fuel fill and vent hose and pipe assembly from the fuel tank.

Installation Procedure

    Object Number: 386369 Size: MH
  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 attaching 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.
  20. Inspect for leaks.
    21. 20.1. Turn the ignition ON for 2 seconds.
    20.2. Turn the ignition OFF for 10 seconds.
    20.3. Turn the ignition ON.
    20.4. Inspect for fuel leaks.

Fuel Tank Replacement Utility with Single Tank

Removal Procedure

    Object Number: 569639 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Drain the fuel tank. Refer to Fuel Tank Draining .
  5. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .
  6. Disconnect the chassis fuel pipes (2) at the fuel tank pipes (1). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

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

    9. Object Number: 570590 Size: SH
  9. Loosen the vent hose clamp (4).
  10. Disconnect the vent hose from the vent pipe.

    11. Object Number: 570588 Size: SH
  11. With the aid of an assistant, support the fuel tank.

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

  12. Remove the fuel tank strap attaching bolts.
  13. Remove the fuel tank straps.
  14. Carefully lower the rear of the fuel tank slightly.
  15. Remove the fuel sender cover on the Suburban only.

    16. Object Number: 373155 Size: SH
  16. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  17. Remove the fuel tank.
  18. Place the fuel tank in a suitable work area.

    19. Object Number: 570582 Size: SH
  19. Remove the fuel feed and return pipes (3) from the fuel sender and the retaining clips.
  20. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  21. Remove the EVAP pipe from the fuel tank roll over valves (2) (4) and the retaining clips (1).
  22. Remove the fuel fill hose and the vent hose from the fuel tank.

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. Connect the fuel feed and return pipes (3) to the fuel sender and the retaining clips.

    4. 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.

  4. Install the fuel fill hose and the vent hose to the fuel tank.

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


    Object Number: 373155 Size: SH
  5. With the aid of an assistant, support and partially raise the fuel tank front end first.
  6. Connect the fuel sender and the fuel pressure sensor electrical connectors.
  7. Install the fuel sender cover on the Suburban only.

    8. Object Number: 570588 Size: SH
  8. Fully raise the fuel tank.
  9. Install the fuel tank straps.
  10. Install the fuel tank strap attaching bolts.

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


    Object Number: 570590 Size: SH
  11. Connect the fuel fill hose and the vent hose to the pipes.

    12. Tighten

        • Tighten the fuel fill hose clamp (2) to 2.5 N·m (22 lb in)
        • Tighten the vent hose clamp (4) 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: 569639 Size: SH
  13. Remove the caps from the fuel and EVAP pipes.
  14. Connect the chassis fuel pipes (2) at the fuel tank pipes (1). Refer to Plastic Collar Quick Connect Fitting Service .
  15. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement or Evaporative Emission Canister Replacement .
  16. Lower the vehicle.
  17. Refill the fuel tank.
  18. Install the fuel filler cap.
  19. Connect the negative battery cable.
  20. Inspect for leaks.
    21. 20.1. Turn the ignition ON for 2 seconds.
    20.2. Turn the ignition OFF for 10 seconds.
    20.3. Turn the ignition ON.
    20.4. Inspect for fuel leaks.

Fuel Tank Replacement Utility with Dual Tanks - Rear Tank

Removal Procedure

    Object Number: 626417 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Lower and remove the under chassis mounted spare tire.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove rear crossmember that holds the spare tire.
  6. Drain the fuel tank. Refer to Fuel Tank Draining .

    7. Object Number: 570565 Size: SH
  7. Loosen the rear tank to front tank fuel fill hose clamp (3).
  8. Disconnect the fuel fill hose (2) from the rear fuel tank.
  9. Disconnect the rear chassis fuel pipe (2) at the fuel sender (1). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the fuel sender electrical connectors.
  11. Disconnect the evaporative emission (EVAP) pipes at the rear tank EVAP pipes (5).
  12. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

    13. Object Number: 570586 Size: SH
  13. With the aid of an assistant, support the fuel tank.

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

  14. Remove the fuel tank strap attaching bolts.
  15. Remove the fuel tank straps.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.

    18. Object Number: 570577 Size: SH
  18. Remove the EVAP pipes from the fuel tank roll over valves (1), (3) and the retaining clips (2).
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 570577 Size: SH
  1. Connect the EVAP pipe to the fuel tank roll over valves (1), (3) and the retaining clips (2).
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .

    3. 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.

  3. Install the fuel fill hose to the fuel tank.

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


    Object Number: 570586 Size: SH
  4. Install the fuel tank.
  5. Install the fuel tank straps.
  6. Install the fuel tank strap attaching bolts.

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


    Object Number: 570565 Size: SH
  7. Connect the fuel fill hose (2) to the rear fuel tank.

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


    Object Number: 561111 Size: SH
  8. Connect the fuel fill pipe ground strap.

    9. Object Number: 569704 Size: SH
  9. Connect the vent hose (3) to the vent pipe (1).

    10. Tighten
    Tighten the vent hose clamp (2) to 2.5 N·m (22 lb in)


    Object Number: 626417 Size: SH
  10. Remove the caps from the fuel and EVAP pipes.
  11. Connect the EVAP pipes at the rear fuel tank EVAP pipes (5). Refer to Plastic Collar Quick Connect Fitting Service .
  12. Connect the fuel sender electrical connectors.
  13. Connect the rear chassis fuel pipe (2) to the fuel sender (1).
  14. Install the rear crossmember that holds the spare tire.
  15. Lower the vehicle.
  16. Install and raise into position the under chassis mounted spare tire.
  17. Refill the fuel tank.
  18. Install the fuel filler cap.
  19. Connect the negative battery cable.
  20. Inspect for leaks.
    21. 20.1. Turn the ignition ON for 2 seconds.
    20.2. Turn the ignition OFF for 10 seconds.
    20.3. Turn the ignition ON.
    20.4. Inspect for fuel leaks.

Fuel Tank Replacement Utility with Dual Tanks - Front Tank

Removal Procedure

    Object Number: 569589 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Drain the fuel tank. Refer to Fuel Tank Draining .
  5. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement .

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

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

    9. Object Number: 570588 Size: SH
  9. With the aid of an assistant, support the fuel tank.

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

  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.

    14. Object Number: 569633 Size: SH
  14. Disconnect the fuel feed return and EVAP (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. Remove the fuel feed and return pipes (3) from the fuel sender and the retaining clips.
  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. Connect the fuel feed and return pipes (3) to the fuel sender and the retaining clips.

    4. Object Number: 569633 Size: SH
  4. With the aid of an assistant, support and partially raise the fuel tank front end first.
  5. Connect the fuel sender and the fuel pressure sensor electrical connectors.
  6. Connect the rear fuel tank to front fuel tank fuel feed pipe (2).
  7. Install the fuel sender cover.

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

    10. 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.

  10. Install the fuel tank strap attaching bolts.

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


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

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


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

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


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

    14. Object Number: 569639 Size: SH
  14. Remove the caps from the fuel and EVAP pipes.
  15. Connect the chassis fuel pipes (2) at the fuel tank pipes (1). Refer to Plastic Collar Quick Connect Fitting Service .
  16. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Install the fuel filler cap.
  20. Connect the negative battery cable.
  21. Inspect for leaks.
    22. 21.1. Turn the ignition ON for 2 seconds.
    21.2. Turn the ignition OFF for 10 seconds.
    21.3. Turn the ignition ON.
    21.4. Inspect for fuel leaks.