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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 next time you need parts for your vehicle, think of 1AAuto.com. Thanks.
In this video, we're going to show you how to replace the fuel tank pressure sensor on this 2002 Chevy Suburban with the 5.3 liter V8 engine. It's the same part and similar process on these Suburbans from 2000 to 2006. The items you'll need are a new fuel tank pressure sensor from 1AAuto.com, an 8 and a 15 millimeter socket and ratchet with an extension, a flat blade screwdriver, a pry bar, 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 can see here. That'll make it a little bit easier when we actually get the tank down. Once you loosen 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.
Now, you want to take a jack stand and just put it underneath your gas tank. 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 it's helpful to have an assistant to just spot the tank and make sure it doesn't go down too far or start to slide or anything. You just want to lower it down just enough so that you can see the sensors on top and then just lift up the tab and disconnect the sensor on the top of your fuel sending unit. Using a flat blade screw driver or a pry bar, just pry the sensor up and out.
On the left is the old sensor. On the right is the new fuel tank pressure sensor from 1A Auto. You can see they're identical, and they'll fit exactly the same. Take your new sensor and push it in to place. Make sure it's all the way down into place and then reconnect your harness.
We'll just fast forward as Don raises the tank. 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 in, and tighten it up, and then, repeat the process for the gas tank strap on the other side. You're all set.
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.
Tools used
Tools used
Disconnect the negative terminal on the battery. Use an 8-millimeter wrench. Slide that off and out of the way. Now, if you have a cover on here, you wanna take that cover off. Normally, it is an 8-millimeter bolt. And then pull this cover off here off of the fuel line, this little cap. And you wanna take a rag and a straight blade screwdriver, and you just want to push on this right here. But if you use a rag, then the fuel won't spray. Just relieve the pressure. And that's good, and there's not much pressure in this system, but just like that. You put the cap back on. The back of the tank, we're just gonna take this line off right here. You just squeeze this connector and twist it back and forth a little bit. Oh, we've got a little fuel out of there. Great. You squeeze that and that comes out. I wanna take this connector off right here that goes to the vent canister. You can either squeeze it with your fingers or just use some pliers and just try to twist it off. Sometimes you got to get underneath there. You could use a pick also. There we go. Slide that one off and then right above it. There we go.
Now, I wanna remove the filter neck hose. Use an 8-millimeter socket or you can use a straight blade screwdriver. Loosen up this one clamp. All right. Now, I'm gonna use a pick. Just get underneath here. Just try to loosen this up. Just twist it. You might not be able to pop this off until we start lowering the tank down, which is okay. We just wanna make sure it's loose. And that's loose. That's good. Now, I'm gonna use a transmission jack to support the fuel tank. It has a special adapter just for fuel tanks. Now, we're gonna take this strap down. We're gonna take this bolt out. I'm gonna use a 15-millimeter socket. You wanna make sure you do this by hand because if you use an impact gun, then you're gonna wreck the nut on the top. Loosen this up. Because it is a J-nut, it will just break. Take that bolt out. I'm just gonna slide the strap down, then you can slide it out up here. Slide it down. Now under normal circumstances, you could just take and do the same on this side. Take the strap out just like that. Use a hand tool. Our J-nut has broken on the top so what we can do is take a 15-millimeter wrench.
Now, we did take the wheel off and we supported the rear axle to make this arm go up a little bit. With the wrench in there, I can loosen up the bolt, hold the nut. All right. Take that bolt out and slide the strap down. Same as the other one, just lift it up, pull it out of that slot. And now we can lower the back of the fuel tank down a little bit. Just try to pry this hose off. Just keep in mind you want as little fuel in the tank as possible. So, you might have to siphon some of the fuel out. Slide that off. All right. Now, we wanna disconnect the lines on the front of the tank. Now, this is the EVAP vapor line. You can just push on these two tabs and disconnect the connector. It's not easy to see, but the fuel pressure line goes right over this crossmember right here and on the backside. You kinda got to feel for it, and I'm gonna have to remove that clip. This is the clip I'm gonna have to lift up. And I'm gonna take a rag just so it doesn't spray everywhere. Just wrap it around and then disconnect it. And there it is, disconnected, just like that. So, you need to make sure there's not a lot of gas in here. And you're gonna tip the tank down in the back. Once this, the filler, gets past the rear differential, then we can back the tank up a little more. It's looking good. That looks good. Looks good. Just slide the tank back a little bit and lower down some more.
And we need to disconnect the electrical connector before we go any further and disconnect this connector right here. Pull the tabs. And then this connector has a little lock on it, slide back on the lock and slide that out. All right. Now, we can lower the tank all the way. All right. To take this sensor out, just get underneath here with some picks and just slide it up. You could use a screwdriver if you wanted to, just like that. When you go to put this in, you can always use a little soapy water on here, just a little bit. Just make it easier to go in. Line it up and press it in just like that. All right. Now, I'm gonna reposition the tank back in. Just make sure it's pretty far back until we get underneath that crossmember first. Remember, once we get close, we're gonna connect the fuel pump, then we're gonna get up a little more. All right. Now, connect that fuel pressure sensor. Make sure it locks in place. That's good. That looks pretty good. Remember, on this backside that you wanna get this hose lined up. All right. Looks good. All right. You can come to the front. You can get this paper line hooked up, lock it in place, then the fuel line. So, it's kinda hard to see.
Now, these straps are different. The one with the shorter part in the back goes in the back right here, line that up there, and then put the other one in the front side. And take the bolts, get the bolts lined up. And tighten these up. And torque this bolt to 30 foot-pounds. Now, we're gonna do the same on the other one. At this point, we can lower the transmission jack, then we're gonna hook these lines up. Line that one up, lock it in place. This lower EVAP line, lock that in place. And then this line right here, get that locked in. That's good. And then we're gonna tighten up this worm clamp and snug it up, not too tight. This is plastic. Just make sure it doesn't...it's not loose. That's pretty good. All right. Connect the negative battery cable and snug it down. Make sure it's tight. Now, before you go to start the vehicle, just take the key, just turn it into the arm position, wait three seconds, turn it off. Just do it again about two or three times. And that's just priming the fuel up. I'll do it one more time and then I should be able to start the vehicle. There we go.
Tools used
Tools used
Tools used
