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Tahoe / Yukon Service Manual

Fuel Tank Replacement (Long Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5596399 Single Use Fasteners and Components Fuel Sender Seal Fuel Tank Filler Vent Hose Strap [2x] Special Tools CH–45722 Fuel Sender Lock Ring Wrench Equivalent regional tools: Special Tools

  1. Relieve the fuel system pressure. Fuel Pressure Relief
  2. Drain the fuel tank. Fuel Tank Draining
  3. Raise and support the vehicle. Lifting and Jacking the Vehicle
Fuel Tank Replacement (Long Wheelbase) — figure 1
Fuel Tank Replacement (Long Wheelbase) — figure 1
  1. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Remove [4x]
  2. Remove both rear stabilizer shaft clamp  (2) from the frame and let the stabilizer shaft hang.
Fuel Tank Replacement (Long Wheelbase) — figure 2
Fuel Tank Replacement (Long Wheelbase) — figure 2
  1. Evaporative Emission Canister Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Evaporative Emission Canister Filter Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  3. Fuel Feed Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Long Wheelbase) — figure 3
Fuel Tank Replacement (Long Wheelbase) — figure 3
  1. Evaporative Emission Canister Solenoid (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Tank Filler Hose Clamp (2) » Loosen
  3. Fuel Tank Filler Hose (3) » Remove
  4. Fuel Tank Filler Vent Hose (4) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Long Wheelbase) — figure 4
Fuel Tank Replacement (Long Wheelbase) — figure 4
  1. Place a suitable adjustable jack under the fuel tank.
  2. Strap fuel tank to jack.
  3. Fuel Tank Strap Bolt (1) » Remove [2x]
  4. Fuel Tank Strap (2) » Remove [2x]
Fuel Tank Replacement (Long Wheelbase) — figure 5
Fuel Tank Replacement (Long Wheelbase) — figure 5
  1. Lower the fuel tank, allowing clearance to access connections at the top of the tank.
  2. Electrical Connector (1) » Disconnect [3x]
  3. Fuel Feed Hose Clip (2) » Disengage
  4. Wiring Harness Retainer (3) » Disengage [2x]
Fuel Tank Replacement (Long Wheelbase) — figure 6
Fuel Tank Replacement (Long Wheelbase) — figure 6
  1. Fuel Tank (1) » Remove
  2. Remove strap retaining fuel tank to jack.
Fuel Tank Replacement (Long Wheelbase) — figure 7
Fuel Tank Replacement (Long Wheelbase) — figure 7
  1. Fuel Tank Shield Retainer (1) » Remove [6x]
  2. Fuel Tank Heat Shield (2) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 8
Fuel Tank Replacement (Long Wheelbase) — figure 8
  1. Tape (1) » Remove
  2. Evaporative Emission Canister Filter Hose (3) @ Fuel Tank Vent Valve Hose Clip (2) » Disengage [2x]
  3. Evaporative Emission Canister Filter Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service
  4. Evaporative Emission Canister Filter Hose (3) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 9
Fuel Tank Replacement (Long Wheelbase) — figure 9
  1. Fuel Tank Filler Vent Hose Strap (1) » Remove and DISCARD [2x]
  2. Evaporative Emission Canister Filter Hose (3) @ Evaporative Emission Canister Hose Clip (2) » Disengage
  3. Evaporative Emission Canister Filter Hose (3) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 10
Fuel Tank Replacement (Long Wheelbase) — figure 10
  1. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Tank Filler Vent Hose (1) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 11
Fuel Tank Replacement (Long Wheelbase) — figure 11
  1. Evaporative Emission Canister Vent Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [2x]
  2. Evaporative Emission Canister Vent Hose (2) » Disconnect [2x] — Plastic Collar Quick Connect Fitting Service
  3. Evaporative Emission Canister Vent Hose (2) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 12
Fuel Tank Replacement (Long Wheelbase) — figure 12
  1. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Disengage [3x]
  2. Fuel Feed Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  3. Fuel Feed Hose (2) » Remove
Fuel Tank Replacement (Long Wheelbase) — figure 13
Fuel Tank Replacement (Long Wheelbase) — figure 13
  1. Fuel Sender Retainer (1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)
Fuel Tank Replacement (Long Wheelbase) — figure 14
Fuel Tank Replacement (Long Wheelbase) — figure 14
  1. Fuel Tank Vent Valve Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Long Wheelbase) — figure 15
Fuel Tank Replacement (Long Wheelbase) — figure 15

  1. Fuel Tank Fuel Pump Module (1) » Remove

  2. Fuel Sender Seal (2) » Remove and DISCARD Installation Procedure

  3. Fuel Sender Seal (2) » Install NEW

  4. Fuel Tank Fuel Pump Module (1) » Install

  5. Fuel Tank Vent Valve Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  6. Fuel Sender Retainer (1) » Install — CH–45722 Fuel Sender Lock Ring Wrench(2)

  7. Fuel Feed Hose (2) » Install

  8. Fuel Feed Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  9. Fuel Feed Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [3x]

  10. Evaporative Emission Canister Vent Hose (2) » Install

  11. Evaporative Emission Canister Vent Hose (2) » Connect [2x] — Plastic Collar Quick Connect Fitting Service

  12. Evaporative Emission Canister Vent Hose (2) @ Fuel Tank Vent Valve Hose Clip (1) » Engage [2x]

  13. Fuel Tank Filler Vent Hose (1) » Install

  14. Fuel Tank Filler Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  15. Evaporative Emission Canister Filter Hose (3) » Install

  16. Evaporative Emission Canister Filter Hose (3) @ Fuel Tank Vent Valve Hose Clip (2) » Engage

  17. Fuel Tank Filler Vent Hose Strap (1) » Install NEW [2x]

  18. Evaporative Emission Canister Filter Hose (3) » Install

  19. Evaporative Emission Canister Filter Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

  20. Evaporative Emission Canister Filter Hose (3) @ Fuel Tank Vent Valve Hose Clip (2) » Engage [2x]

  21. Tape (1) » Install

  22. Fuel Tank Heat Shield (2) » Install

  23. Fuel Tank Shield Retainer (1) » Install [6x]

  24. Place a suitable adjustable jack under the fuel tank.

  25. Strap fuel tank to jack.

  26. Raise the fuel tank  (1), allowing access to connections at the top of the tank.

  27. Wiring Harness Retainer (3) » Engage [2x]

  28. Fuel Feed Hose Clip (2) » Engage

  29. Electrical Connector (1) » Connect [3x]

  30. Raise the tank to the installed position.

  31. Fuel Tank Strap (2) » Install [2x]

  1. Fuel Tank Strap Bolt (1) » Install and tighten [2x] — Fastener Specifications

  2. Remove strap retaining fuel tank to jack.

  3. Fuel Tank Filler Vent Hose (4) » Connect — Plastic Collar Quick Connect Fitting Service

  4. Fuel Tank Filler Hose (3) » Install

  5. Fuel Tank Filler Hose Clamp (2) » Tighten — Fastener Specifications

  6. Evaporative Emission Canister Solenoid (1) » Connect — Plastic Collar Quick Connect Fitting Service

  7. Fuel Feed Hose (3) » Connect — Plastic Collar Quick Connect Fitting Service

  8. Evaporative Emission Canister Filter Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  9. Evaporative Emission Canister Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

  10. Raise rear stabilizer shaft into installed position.

  11. Rear Stabilizer Shaft Clamp (2) » Install [2x]

  12. Rear Stabilizer Shaft Insulator Clamp Bolt (1) » Install and tighten [4x] — Fastener Specifications

  13. Lower the vehicle.

  14. Refill the fuel tank.

  15. Inspect for fuel leaks.