GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Tank Assembly

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REMOVAL & INSTALLATION



See Figures 1 through 7



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Fig. Fig. 1 : Common fuel tank filler neck installation



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Fig. Fig. 2: Fuel tank mounting-vehicles equipped with shield package



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Fig. Fig. 3 : Failure to tag the fuel lines could lead to confusion during installation



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Fig. Fig. 4 : One of the retaining straps may be used to help retain the tank while connecting hoses and wires



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Fig. Fig. 5 : If equipped, make sure the isolators are positioned between the straps and tank



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Fig. Fig. 6 : Secure the retaining straps using the fasteners



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Fig. Fig. 7 : Most tanks on these vehicles are retained using 2 straps

Except With Shield Package
  1. Properly drain the fuel tank, then disconnect the negative battery cable.
  2.  
  3. If not done already, raise and support the rear of the truck safely using jackstands.
  4.  
  5. If equipped on late-model vehicles, loosen and remove the tank plastic shield.
  6.  
  7. Loosen the retaining clamp and disconnect the tank filler hose from the tank neck.
  8.  

If fuel and vapor hoses or pump/sending unit wiring can be accessed at this time, they may be tagged and disconnected. If not, wait for the retaining straps to be loosened and lower the tank slightly for access.

  1. Tag and disconnect and accessible wiring or hoses from the top of the fuel tank.
  2.  
  3. Have and assistant support the fuel tank, then remove the fuel tank-to-vehicle straps and, if equipped, the isolation strips. If no assistant is available, position a floor jack to support the tank while the straps are removed.
  4.  
  5. Lower the tank slightly, then remove the sending unit or sending unit/pump wires, hoses and ground strap. Be sure to label all connections to ease installation.
  6.  
  7. Carefully lower the fuel tank from the vehicle and store in a safe place.
  8.  

To install:
  1. Raise the tank partially into position in the vehicle. If you are working without an assistant, you may wish to loosely install one of the retaining straps and use a floor jack to support the tank at an angle so there is access to the sending unit or sending unit/pump assembly (as applicable).
  2.  
  3. Connect the fuel/vapor hoses and wiring to the top of the fuel tank, as tagged during removal.
  4.  
  5. Carefully raise the fuel tank so it is fully into position and loosely secure the retaining straps. Make sure the wires and hoses are not pinched or damaged when raising the tank. Also, be sure that the isolation strips (if used) are positioned between the retaining straps and the fuel tank.
  6.  
  7. It may be easier to connect the fuel filler hose to the tank neck at this time. If desired, connect the hose and secure the clamp.
  8.  
  9. Tighten the fuel tank retaining strap fasteners to specification. Tighten the strap nuts to 33 ft. lbs. (45 Nm).
  10.  
  11. If not done earlier, connect the tank filler hose to the tank neck and secure using the clamp.
  12.  
  13. If equipped, install and secure the tank plastic shield.
  14.  
  15. Remove the jackstands and carefully lower the rear of the truck.
  16.  
  17. Refill the fuel tank and install the filler cap, then check for leaks.
  18.  
  19. Connect the negative battery cable.
  20.  

Equipped With Shield Package
  1. Properly drain the fuel tank, then disconnect the negative battery cable.
  2.  
  3. Raise and support the rear of the truck safely using jackstands.
  4.  
  5. Remove the shield forward support and bracket.
  6.  
  7. While supporting the shield and tank assembly with the help of both an assistant and a floor jack, remove the remaining bolts holding the assembly to the frame, then lower it sufficiently for access to the hoses and wires.
  8.  
  9. Tag and disengage the hoses and wires from the sending unit assembly.
  10.  
  11. Carefully lower the fuel tank and shield from the vehicle, then if necessary for service or replacement, separate the tank from the shield.
  12.  

To install:
  1. If separated, install the tank to the shield.
  2.  
  3. Carefully raise the tank and shield assembly partially into position with the help of an assistant and a floor jack.
  4.  
  5. Connect the wiring and hoses to the sending unit assembly, as tagged during removal.
  6.  
  7. Raise the tank and shield assembly fully into position, then secure to the frame using the lower retaining bolts.
  8.  
  9. Install the shield forward support bracket.
  10.  
  11. Remove the jackstands and carefully lower the rear of the truck.
  12.  
  13. Refill the fuel tank and install the filler cap, then check for leaks.
  14.  
  15. Connect the negative battery cable.
  16.  

 
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