GM Astro/Safari 1985-1996 Repair Guide

Fuel Tank Assembly



See Figures 1 and 2

Click image to see an enlarged view

Fig. Fig. 1: Fuel filler neck assembly

Click image to see an enlarged view

Fig. Fig. 2: The fuel tank bolts must be tightened alternately to prevent distortion of the fuel tank bottom

  1. Disconnect the negative battery cable from the battery.

Be sure to keep a Class B (dry chemical) fire extinguisher nearby.

Due to the possibility of fire or explosion, never drain or store gasoline in an open container.

  1. Using a hand pump or a siphon hose, drain the gasoline into an approved container.
  3. Raise and support the vehicle on jackstands.
  5. Support the fuel tank and remove the fuel tank-to-vehicle straps.
  7. Lower the tank slightly, then remove the sender unit wires, the hoses and the ground strap.
  9. Remove the fuel tank from the vehicle.

To install:

Be sure to connect the sender unit wires and the hoses before final installation of the fuel tank.

  1. Align the insulator strips and position the tank into the vehicle. Torque the inner fuel tank bolts to 26 ft. lbs. (35 Nm) and the outer strap bolts to 30 ft. lbs. (40 Nm) in alternating sequence. Torque the nuts to 26 ft. lbs. (35 Nm). This must be done to prevent the bottom of the tank from bowing up and effecting the fuel level sender.
  3. Make sure all hoses and electrical connectors are secure and properly routed to prevent damage.
  5. Lower the vehicle, connect the negative battery cable, start the engine and check for leaks and proper operation.