How To Replace Fuel Tank 2000-06 Chevy Suburban
Created on: 2014-06-19
Check out this video to learn how to replace the fuel tank on your 00-06 Chevy Suburban.
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step 1 :Disconnecting the Fuel Lines
- Loosen the two hose clamps on the fuel filler hose and the fuel vapor hose
- Support the fuel tank with a jack
- Remove the 15mm bolts from the gas tank straps
- Have an assistant hold one end of the gas tank
- Lower the jack on the gas tank
- Pull the plastic fuel hose free from the bracket on top of the gas tank
- Disconnect the plastic fuel hose and remove it from the brackets on the gas tank
- Disconnect the fuel pump and sending unit wiring harnesses
- Disconnect the hose from the fuel line on the fuel pump and sending unit
- Unclip the hoses on the front of the gas tank
- Remove the hoses from the fuel pump sending unit
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step 2 :Removing the Gas Tank
- Plug the holes on the back of the tank with tape if there is fuel remaining inside
- Remove the jack stand and have an assistant lower the back end of the gas tank down
- Slide the gas tank out
- Disconnect the plastic fuel hose
- Dump any remaining fuel into a gas canister
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step 3 :Installing the New Gas Tank
- Insert the gas tank, front end first
- Connect the plastic fuel hose
- Clip the fuel hoses into the brackets on the front of the gas tank
- Push the tank closer into place
- Support the tank on a jack
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step 4 :Connecting the Fuel Lines
- Connect the hoses to the fuel lines on the fuel pump
- Connect the fuel pump and sending unit wiring harness
- Clip the fuel hoses into the brackets on the gas tank
- Connect the plastic fuel line and clip it in place
- Jack the gas tank into place
- Remove any tape plugging the holes
- Connect the fuel filler hose and the fuel vapor hose
- Tighten the clamps on the fuel filler hose and the fuel vapor hose
- Tighten the 15mm bolts to the gas tank straps
Tools needed
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Socket Extensions
Flat Blade Screwdriver
15mm Socket
Pry Bar
Jack Stands
8mm Socket
Duct Tape
Ratchet
Floor Jack
Needle nose pliers
Assistant
Brought to you by 1AAuto.com, your source for quality replacement parts and the best service on the Internet.
Hi, I'm Don from 1A Auto. I hope this how-to video helps you out, and the next time you need a part for your vehicle, think of 1AAuto.com. Thanks.
In this video, we're going to show you how to replace the fuel tank on this 2002 Chevy Suburban. The items you'll need for this are an 8mm and 15 millimeter socket and ratchet with an extension, a flat blade screwdriver, a pry bar, pliers, an assistant, and jack and jack stands.
Start off by loosening these two hose clamps. It's that hose, but we actually end up loosening the hose clamp that's up near the spare tire on the other end of the hose from where we pointed as you could see here. That will make it a little bit easier when we actually get the tank down. Once you've loosened those hose clamps just pull those hoses free. You may need to use a pry bar to help get that free. You can also use a large flat blade screwdriver.
Support the middle of your fuel tank with a jack. Next you want to remove the gas tank straps. To do that you want to remove this 15 millimeter bolt and this one on the other strap. We'll just fast-forward as Don does that. Now just pull that strap up and out of that slot. Do the same thing with the other one. Now have an assistant hold one end of the gas tank while you lower the jack and re-position it.
On top of the gas tank just pull this hose free from the bracket. Then go down to the end that's lowered and you'll see this hose. Just pull that free and then pull the hose from this bracket on the side of the tank. Do the same thing for the one below it. Then just keep framing those hoses by pulling them out of the brackets that line the tank.
Now, on your fuel pump and sending unit you want to just push the tabs on the harnesses and disconnect them. Then using a pair of pliers just push the tabs on this hose and pry the hose off. Just pull them free. Clip the hoses that are closer to the front of the gas tank. Then reach back behind here and just pull up on these hoses you disconnected from the fuel pump sending unit earlier.
If you have fuel in the tank you'll want to plug the holes at the back. We use duct tape just to prevent the fuel from spilling out as you tip the tank down. We want to make sure it has no leaks. Then remove the jack stand, lower the back end of the gas tank down, and just carefully slide it out. Then you can set your gas tank down and then just disconnect this hose. If the gas tank is too heavy just dump some of the gas out.
To reinstall, get the fuel tank situated and put the front end up in first. You can reconnect that hose in the end there that you can only really access when the tank's down. Then you just want to clip these hoses back into that bracket and push that down in the tank. Then push the tank back up into place, not all the way because you still have some things to connect up there, but preliminarily. Then put the stand underneath it with the back end lower than the front. Then push these hoses back into your sending unit.
Reconnecting the fuel lines is kind of fun. I use that word lightly. They can be difficult but it seems like when you get them right they will snap right in with no problem. But we ended up probably messing with ours for about a minute and then just position them correctly and they go right in and snap right in. Reconnect those two harnesses. Then just push these hoses back down into this bracket. Make sure you push them into the other brackets all the way up to the back of the tank. Okay, this goes back here. Then push this hose back into place and re-clip it to the side of the tank. We'll just fast-forward as Don raises the tank the rest of the way back up.
Now you just want to remove that duct tape. Now reconnect these two hoses and slide the hose clamps into place. Then just tighten them up with your socket and ratchet. Slide the rear gas tank strap into the slot and then feed it up with the bolt end and tighten it up. Then repeat the process for the gas tank strap on the other side.
We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.
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