GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Express 🢒 Engine 🢒 Engine Controls and Fuel - 4.3L 🢒 Fuel Tank Replacement

Fuel Tank Replacement with E26

Removal Procedure

    Object Number: 1938255 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.

    6. Object Number: 1938257 Size: SH
  6. Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
  7. Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.

    10. Object Number: 1938258 Size: SH
  10. Support the fuel tank with an adjustable jack.
  11. Remove the fuel tank strap bolts (1).
  12. Remove the fuel tank straps (2).
  13. With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
  14. Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
  15. With the aid of the assistant, completely lower the fuel tank.
  16. With the aid of the assistant, place the fuel tank in a suitable work area.
  17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.

    18. Object Number: 1938261 Size: SH
  18. Remove the fuel tank shield push on retainers (2).
  19. Remove the fuel tank shield (1) from the fuel tank clips.

    20. Object Number: 1938263 Size: SH
  20. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  21. Remove the fuel feed pipe from the fuel tank clips (2 and 3).
  22. Remove the fuel feed pipe (1) from under the EVAP front pipe.

    23. Object Number: 1938265 Size: SH
  23. Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Remove the EVAP front pipe (1) from under the EVAP pipe.

    25. Object Number: 1938268 Size: SH
  25. Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  26. Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
  27. Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  28. Disconnect the EVAP pipe quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  29. Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
  30. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  31. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .

Installation Procedure

    Object Number: 1938268 Size: SH
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .
  2. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  3. Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4) .
  4. Connect the EVAP pipe quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.

    8. Object Number: 1938265 Size: SH
  8. Install and route the EVAP front pipe (1) under the EVAP line.
  9. Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .

    10. Object Number: 1938263 Size: SH
  10. Install and route the fuel feed pipe (1) under the EVAP front pipe.
  11. Connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Install the fuel feed pipe to the fuel tank clips (2 and 3).

    13. Object Number: 1938261 Size: SH
  13. Install the fuel tank shield onto the tank clips (1).
  14. Install the fuel tank shield push on retainers (2).

    15. Object Number: 1938258 Size: SH
  15. With the aid of an assistant, place the fuel tank on the adjustable jack.
  16. With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
  17. Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
  18. With the aid of the assistant, completely raise the fuel tank.
  19. Install the fuel tank straps (2).

    20. Notice: Refer to Fastener Notice in the Preface section.

  20. Install the fuel tank strap bolts (1).

    21. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  21. Remove the adjustable jack from under the fuel tank.

    22. Object Number: 1938257 Size: SH
  22. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
  23. Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .

    25. Object Number: 1938255 Size: SH
  25. Install the fuel tank fill hose to the fuel tank.
  26. Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  27. Tighten the fuel fill hose clamp (2) at the fuel tank.

    28. Tighten
    Tighten the clamp to 2.75 N·m (24 lb in).

  28. Refill the fuel tank.
  29. Install the fuel cap.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  31. Perform the following procedure in order to inspect for leaks:
    32. 31.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    31.2. Turn the ignition OFF for 10 seconds.
    31.3. Turn the ignition ON, with the engine OFF.
    31.4. Inspect for fuel leaks.

Fuel Tank Replacement without E26

Removal Procedure

    Object Number: 1944010 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.

    6. Object Number: 1938257 Size: SH
  6. Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
  7. Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.

    10. Object Number: 1938258 Size: SH
  10. Support the fuel tank with an adjustable jack.
  11. Remove the fuel tank strap bolts (1).
  12. Remove the fuel tank straps (2).
  13. With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
  14. Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
  15. With the aid of the assistant, completely lower the fuel tank.
  16. With the aid of the assistant, place the fuel tank in a suitable work area.
  17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.

    18. Object Number: 1938261 Size: SH
  18. Remove the fuel tank shield push on retainers (2).
  19. Remove the fuel tank shield (1) from the fuel tank clips.

    20. Object Number: 1938263 Size: SH
  20. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  21. Remove the fuel feed pipe from the fuel tank clips (2 and 3).
  22. Remove the fuel feed pipe (1) from under the EVAP front pipe.

    23. Object Number: 1944096 Size: SH
  23. Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Remove the EVAP front pipe (1) from under the EVAP pipe.

    25. Object Number: 1938268 Size: SH
  25. Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  26. Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
  27. Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  28. Disconnect the EVAP pipe quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  29. Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
  30. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  31. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .

Installation Procedure

    Object Number: 1938268 Size: SH
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .
  2. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  3. Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4) .
  4. Connect the EVAP pipe quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.

    8. Object Number: 1944096 Size: SH
  8. Install and route the EVAP front pipe (1) under the EVAP line.
  9. Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .

    10. Object Number: 1938263 Size: SH
  10. Install and route the fuel feed pipe (1) under the EVAP front pipe.
  11. Connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Install the fuel feed pipe to the fuel tank clips (2 and 3).

    13. Object Number: 1938261 Size: SH
  13. Install the fuel tank shield onto the tank clips (1).
  14. Install the fuel tank shield push on retainers (2).

    15. Object Number: 1938258 Size: SH
  15. With the aid of an assistant, place the fuel tank on the adjustable jack.
  16. With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
  17. Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
  18. With the aid of the assistant, completely raise the fuel tank.
  19. Install the fuel tank straps (2).

    20. Notice: Refer to Fastener Notice in the Preface section.

  20. Install the fuel tank strap bolts (1).

    21. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  21. Remove the adjustable jack from under the fuel tank.

    22. Object Number: 1938257 Size: SH
  22. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
  23. Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .

    25. Object Number: 1944010 Size: SH
  25. Install the fuel tank fill hose to the fuel tank.
  26. Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  27. Tighten the fuel fill hose clamp (2) at the fuel tank.

    28. Tighten
    Tighten the clamp to 2.75 N·m (24 lb in).

  28. Refill the fuel tank.
  29. Install the fuel cap.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  31. Perform the following procedure in order to inspect for leaks:
    32. 31.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    31.2. Turn the ignition OFF for 10 seconds.
    31.3. Turn the ignition ON, with the engine OFF.
    31.4. Inspect for fuel leaks.