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Tahoe / Yukon Service Manual

Fuel Tank Replacement (Short Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5536174 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 (Short Wheelbase) — figure 1
Fuel Tank Replacement (Short 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 (Short Wheelbase) — figure 2
Fuel Tank Replacement (Short Wheelbase) — figure 2
  1. Evaporative Emission Hose (1) » Disconnect [2x] — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Short Wheelbase) — figure 3
Fuel Tank Replacement (Short Wheelbase) — figure 3
  1. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Short Wheelbase) — figure 4
Fuel Tank Replacement (Short Wheelbase) — figure 4
  1. Fuel Tank Filler Hose Clamp (1) » Loosen
  2. Fuel Tank Filler Hose (2) » Remove
  3. Evaporative Emission Hose (3) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Short Wheelbase) — figure 5
Fuel Tank Replacement (Short Wheelbase) — figure 5
  1. Fuel Tank Filler Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
Fuel Tank Replacement (Short Wheelbase) — figure 6
Fuel Tank Replacement (Short Wheelbase) — figure 6
  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 (Short Wheelbase) — figure 7
Fuel Tank Replacement (Short Wheelbase) — figure 7
  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
Fuel Tank Replacement (Short Wheelbase) — figure 8
Fuel Tank Replacement (Short Wheelbase) — figure 8
  1. Fuel Tank (1) » Remove
  2. Remove strap.
Fuel Tank Replacement (Short Wheelbase) — figure 9
Fuel Tank Replacement (Short Wheelbase) — figure 9
  1. Fuel Tank Shield Retainer (1) » Remove [6x]
  2. Fuel Tank Heat Shield (2) » Remove
Fuel Tank Replacement (Short Wheelbase) — figure 10
Fuel Tank Replacement (Short Wheelbase) — figure 10
  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 (Short Wheelbase) — figure 11
Fuel Tank Replacement (Short Wheelbase) — figure 11
  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
Fuel Tank Replacement (Short Wheelbase) — figure 12
Fuel Tank Replacement (Short Wheelbase) — figure 12
  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 (Short Wheelbase) — figure 13
Fuel Tank Replacement (Short Wheelbase) — figure 13
  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 (Short Wheelbase) — figure 14
Fuel Tank Replacement (Short Wheelbase) — figure 14
  1. Fuel Tank Filler Vent Hose (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
  2. Fuel Tank Filler Vent Hose (2) » Remove
Fuel Tank Replacement (Short Wheelbase) — figure 15
Fuel Tank Replacement (Short Wheelbase) — figure 15
  1. Fuel Sender Retainer(1) » Remove — CH–45722 Fuel Sender Lock Ring Wrench(2)
Fuel Tank Replacement (Short Wheelbase) — figure 16
Fuel Tank Replacement (Short Wheelbase) — figure 16

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

  2. Disconnect vent hose.

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

  4. Fuel Sender Seal (2) » Install NEW

  5. Connect vent hose.

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

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

  8. Fuel Tank Filler Vent Hose (2) » Install

  9. Fuel Tank Filler Vent Hose (2) » Connect — Plastic Collar Quick Connect Fitting Service

  10. Fuel Feed Hose (2) » Install

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

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

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

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

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

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

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

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

Fuel Tank Replacement (Short Wheelbase) — figure 17
Fuel Tank Replacement (Short Wheelbase) — figure 17

  1. Evaporative Emission Canister Filter Hose (2) » Install

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

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

  4. Fuel Tank Heat Shield (2) » Install

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

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

  7. Strap fuel tank to jack.

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

  9. Wiring Harness Retainer (3) » Engage

  10. Fuel Feed Hose Clip (2) » Engage

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

  12. Raise the tank to the installed position.

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

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

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

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

  4. Fuel Tank Filler Hose (2) » Install

  5. Fuel Tank Filler Hose Clamp (1) » Tighten — Fastener Specifications

  6. Fuel Feed Hose (1) @ Fuel Feed Pipe (2) » Connect — Plastic Collar Quick Connect Fitting Service

  7. Evaporative Emission Hose (1) » Connect [2x] — Plastic Collar Quick Connect Fitting Service

  8. Raise rear stabilizer shaft into installed position.

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

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

  11. Lower the vehicle.

  12. Refill the fuel tank.

  13. Inspect for fuel leaks.