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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 878 (ENGINE CONTROLS - 8.1L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (FRONT TANK)REMOVAL PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Removal Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Removal Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2001 GMC Yukon XL, 2001 GMC Sierra, 2001 GMC Cab & Chassis Sierra, 2001 GMC C3500 HD, and 2001 Chevrolet Suburban. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Evaporative Emission Canister
    GM569589Courtesy of GENERAL MOTORS COMPANY
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Drain the fuel tank. Refer to Fuel Tank Draining (Front Tank) , Fuel Tank Draining (Rear Tank) , Fuel Tank Draining (Cab/Chassis) .
  4. Remove the evaporative emission (EVAP) canister. Refer to Evaporative Emission Canister Replacement (Utility) , Evaporative Emission Canister Replacement (Cab/Chassis) , Evaporative Emission Canister Replacement (Pickup) .
    5. Fig 2: Vent Valve Pipe
    GM625803Courtesy of GENERAL MOTORS COMPANY
  5. Disconnect the EVAP vent pipe (3) at the fuel tank clip (5).
    6. Fig 3: Fuel Tank Fill And Vent Hoses
    GM569669Courtesy of GENERAL MOTORS COMPANY
  6. Loosen the vent hose clamp (7).
  7. Disconnect the vent hose (6) from the fuel tank.
    8. Fig 4: Fuel Fill Hose
    GM570570Courtesy of GENERAL MOTORS COMPANY
  8. Disconnect the fuel fill hose (2) from the fuel tank.
    9. Fig 5: Fuel Tank Strap
    GM570588Courtesy of GENERAL MOTORS COMPANY
  9. With the aid of an assistant, support the fuel tank.
  10. Remove the fuel tank strap attaching bolts.
  11. Remove the fuel tank straps.
  12. Carefully lower the rear of the fuel tank slightly.
  13. Remove the fuel sender cover, on the suburban only.
    14. Fig 6: Fuel Feed, Return, And EVAP Pipes At Fuel Sender
    GM569633Courtesy of GENERAL MOTORS COMPANY
  14. Disconnect the fuel feed, return, and evaporative emission (EVAP) pipes (1, 2, 3) at the fuel sender.
  15. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
    18. Fig 7: Fuel Feed And Return Pipes
    GM570582Courtesy of GENERAL MOTORS COMPANY
  18. Disconnect the EVAP pipe from the fuel tank roll over valves (2, 4) and the retaining clips (1).
  19. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  20. Cap the fuel and EVAP pipes in order to prevent possible fuel system contamination.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.