2004 Chevrolet ClassicFACTORY OEM SERVICE PROCEDURE

Removal Procedure

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    4. Fig 1: Disconnecting Quick Connect Fitting from Fuel Filter
    GM54520Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the quick-connect fitting at the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  5. Disconnect the fuel return pipe quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle.
  7. Remove the exhaust heat shield.
  8. Loosen the fuel filler hose clamp at the fuel tank.
  9. Disconnect the fuel filler hose from the fuel tank.
  10. Disconnect the evaporative emission (EVAP) vapor pipe from the EVAP canister.
  11. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
    12. Fig 2: View of Fuel Tank
    GM49897Courtesy of GENERAL MOTORS CORP.
  12. With the aid of an assistant, support the fuel tank (1).
  13. Disconnect the fuel tank retaining straps.
  14. Lower the fuel tank.
  15. Remove the fuel sender assembly from the tank. Refer to Fuel Sender Assembly Replacement .
Factory Service Tools

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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.

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