Fuel Tank Replacement (Tahoe/Yukon)

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39765 fuel sender locknut wrench.

CAUTION: Provide additional support when a vehicle is on a hoist in the following ways:
^ Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
^ Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Drain the fuel from the tank.
3. Relieve the fuel system pressure.
4. Raise the vehicle.
5. Loosen the filler neck hose clamp at the fuel tank and disconnect the fuel tank filler neck from the fuel tank.




6. Support the fuel tank and loosen the tank straps and remove insulator strips, if equipped.




7. With the aid of an assistant lower and support the fuel tank and shield.
8. Clean all fuel pipe connections and surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system. Disconnect the fuel feed and vapor hoses.
9. Disconnect the electrical connections at the sender.
10. Remove the fuel tank straps.
11. Remove the fuel tank and place in a suitable work area.




12. Remove the fuel sender assembly and seal ring, using tool J 39765. Discard the old seal ring.

INSTALLATION PROCEDURE




1. Install the new seal ring and reinstall the sender using tool J 39765.
2. With the aid of an assistant, raise and support the tank to allow reconnection of the fuel feed and vapor hoses and the electrical connections at the sender.




3. Raise the tank fully.
4. Install the fuel tank straps and fastening hardware.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.




5. Reinstall the fuel tank filler neck to the tank. Tighten the clamp.

NOTE:
^ Refer to Fuel Tank Strap Nuts Notice in Cautions and Notices.
^ Refer to Fastener Notice in Cautions and Notices.




6. Install the fuel tank straps with insulator strips in place.

Tighten
Tighten the strap nuts to 13 N.m (115 lb in).




7. Install the fuel tank off-road shield, if equipped.
8. Replenish the fuel in the tank. Reinstall the fuel tank filler cap.
9. Reconnect the negative battery cable. If a memory retention device was not used, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
10. Check for fuel leaks.
10.1. Turn ON the ignition switch for 2 seconds.
10.2. Turn OFF the ignition switch for 10 seconds.
10.3. Again, turn the ignition switch to the ON position.
10.4. Check for fuel leaks.