GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2003 🢒 Envoy - 4WD 🢒 General Information 🢒 General Information 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 730806 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. Remove the frame brace. Refer to Frame Brace Replacement in Frame and Underbody.
  4. Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement in Frame and Underbody.
  5. Loosen the fuel hose clamp (1) at the fuel tank.
  6. Separate the fuel hose (2) from the fuel tank.

    7. Object Number: 887435 Size: SH
  7. Disconnect the fuel tank pressure sensor electrical connector (3).
  8. Disconnect the evaporative emission (EVAP) vent valve electrical connector (2).

    9. Object Number: 899732 Size: SH
  9. Disconnect the fuel feed, return and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.

    11. Object Number: 887432 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 bolts (1).
  13. Remove the fuel tank straps (2).
  14. Carefully lower the fuel tank.

    15. Object Number: 887435 Size: SH
  15. Disconnect the fuel sender electrical connector (1).
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
  18. If the fuel tank is not being replaced, go to the Installation Procedure.

Disassembly Procedure

    Object Number: 887437 Size: SH
  1. Remove the EVAP vent valve (1). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .
  2. Remove the fuel filter (8). Refer to Fuel Filter Replacement .
  3. Disconnect the fuel feed and return pipes from the fuel sender (5). Refer to Plastic Collar Quick Connect Fitting Service .
  4. Remove the fuel feed and return pipes from the retaining clip (7).
  5. Remove the EVAP vent valve pipe.
  6. Disconnect the EVAP vapor pipe from the fill limiter vent valve (4), and the front and rear rollover valves (2, 6). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Remove the EVAP vapor pipes.
  8. Remove the fuel sender assembly (5) from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  9. Remove the EVAP canister (3) Refer to Evaporative Emission Canister Replacement .

Assembly Procedure

    Object Number: 887437 Size: SH
  1. Install the EVAP canister (3) Refer to Evaporative Emission Canister Replacement .
  2. Install the fuel sender assembly (5) to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  3. Connect the EVAP vapor pipe to the fill limiter vent valve (4) and the front and rear rollover valve (2, 6). Refer to Plastic Collar Quick Connect Fitting Service .
  4. Install the EVAP vent valve pipe.
  5. Connect the fuel feed and return pipes to the fuel sender (5). Refer to Plastic Collar Quick Connect Fitting Service .
  6. Install the fuel feed and return pipes to the retaining clip (7).
  7. Install the fuel filter (8). Refer to Fuel Filter Replacement .
  8. Install the EVAP vent valve (1). Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement .

Installation Procedure

    Object Number: 887435 Size: SH
  1. With the aid of an assistant, position and support the fuel tank.
  2. Connect the fuel sender electrical connector (1).

    3. Object Number: 887432 Size: SH
  3. Install the fuel tank straps (2).

    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 tank strap bolts (1).

    5. Tighten
    Tighten the bolts to 32 N·m (24 lb ft).


    Object Number: 899732 Size: SH
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel feed, return and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .

    7. Object Number: 887435 Size: SH
  7. Connect the fuel tank pressure sensor electrical connector (3).
  8. Connect the EVAP vent valve electrical connector (2).

    9. Object Number: 730806 Size: SH
  9. Connect the fuel hose (2) to the fuel tank.

    10. Tighten
    Tighten the clamp (1) to 2.5 N·m (22 lb in).

  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel fill cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  14. Inspect for leaks.
    15. 14.1. Turn the ignition ON, with the engine OFF for 10 seconds.
    14.2. Turn the ignition OFF for 10 seconds.
    14.3. Turn the ignition ON, with the engine OFF.
    14.4. Inspect for fuel leaks.
  15. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement in Frame and Underbody.
  16. Install the frame brace. Refer to Frame Brace Replacement in Frame and Underbody.
  17. Lower the vehicle.