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How To Remove Fuel Tank 02-09 GMC Envoy XL

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How To Remove Fuel Tank 02-09 GMC Envoy XL

Created on: 2014-11-12

This video will show how to properly depressurize and disconnect and later reconnect the fuel lines to access and replace the fuel tank yourself

  1. step 1 :Depressurizing the Fuel System
    • Pull up the fuse box cover
    • Start the vehicle
    • Remove the fuel pump relay
    • Allow the engine to run down
    • Turn off the vehicle
    • Push in the fuel pump relay
    • Push on the fuse box cover
  2. step 2 :Disconnecting the Fuel Hoses
    • Raise and secure the vehicle
    • Have a drain pan ready
    • Pull off the fuel drain cap
    • Push the fuel drain valve with a flat blade screwdriver
    • Drain the fuel
    • Disconnect the fuel lines with pliers
    • Loosen the fuel filler neck hose clamp
    • Pull the hose off of the filler neck
  3. step 3 :Removing the Fuel Tank
    • Support the fuel tank with a jack
    • Disconnect the fuel pump wiring harness
    • Remove the four 15mm sockets from the fuel tank cross bar
    • Apply rust penetrant to the gas tank strap bolts
    • Remove the 15mm bolts from the gas tank straps
    • If necessary, cut the bolts off with a reciprocating saw
    • Pull off the front fuel tank strap
    • Bend down the rear fuel tank strap
    • Lower the jack
    • Disconnect the two wiring harnesses at the top of the fuel tank
    • Lower the fuel tank
  4. step 4 :Installing the Fuel Tank
    • Lift the fuel tank into place
    • Support the fuel tank with a jack
    • Connect the wiring harnesses
    • Put the front fuel tank strap into place
    • Insert the 15mm bolt into the strap
    • Remove the four 11mm bolts from the driveshaft
    • Thread the bolts partially
    • Tap out the driveshaft with a hammer
    • Pry out the driveshaft with a pry bar
    • Pull the driveshaft aside
    • Put the rear fuel tank strap into place
    • Insert the 15mm bolt into the strap
    • Put the driveshaft into place
    • Insert the four 11mm bolts into the driveshaft
    • Lower the jack
    • Connect the remaining wiring harnesses
  5. step 5 :Connecting the Fuel Lines
    • Push the hose onto the filler neck
    • Tighten the filler neck hose clamp
    • Push the three fuel lines onto the fuel tank
    • Put the fuel tank crossbar into place
    • Insert the four 15mm bolts into the crossbar
    • Lower the vehicle to the ground

Tools needed for replacement

  • General Tools

    Reciprocating Saw

    Hammer

    Jack Stands

    Drain Pan

    Floor Jack

  • Materials, Fluids, and Supplies

    Rust Penetrant

  • Pliers, Cutters & misc Wrenches

    Needle nose pliers

  • Ratchets & Related

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    15mm Socket

    7mm Socket

  • Wrenches - Metric

    11mm Wrench

Installation Video
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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 Mike 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 remove and replace the fuel tank in this 2003 GMC Envoy XL and the items you'll need for this are a 7mm and 15mm socket and ratchet, an 11mm wrench, a flat blade screwdriver, pliers, a drip pan, jack and jack stands, and depending on the condition of your fuel tank strap holds, you may need a reciprocating saw, as well.

Start out by locating the relay for your fuel pump and there is a fuse box under the hood right behind the battery. Ours is number 41, which is that one, there and start up your vehicle. Pull this relay out and it quits as it runs out of fuel. Pull that fuse relay and eventually the engine quits as it loses fuel. Then put the relay back in after you have turned off the key. You can put the relay back in. Make sure you don't turn the key back on again. That will energize the system, and then put that back, and now you can take off the underneath in front of the fuel tank. This is the drain for the fuel and we're just going to use a screwdriver to cap off and press in the valve and that will allow the fuel to drain and obviously, we have a drip pan underneath to catch it.

The next step will be to disconnect the fuel lines. We push in on the fuel lines and then there is basically a clip that you press the ears together. You can see it better on this one. Use the pliers, press the ears in on the clip and then you should be able to pull the fuel line off. Some of them come off easier than others. You'll want to disconnect three fuel lines, total: the one coming from the front to the fuel filter and then the two up top here. On the flat spot on the top and bottom of this, push the fuel line a little bit, try and get it loosened up. Now, at the back of the vehicle, you just want to loosen up this host clamp on the fuel filler neck. Now, pull that hose from the filler neck. It takes a little bit of force. Also, you want to check the condition of your fill neck. At 1A Auto, we also sell new filler necks. If yours is rusted or anything like that, it may be time to replace it.

Now, just lift up on the tab and disconnect that harness and then you want to remove these four 15mm bolts on this cross bar and we'll fast forward as Mike does that and pulls that cross bar down and you can use a socket and ratchet, but we're going to use some air powered tools to speed it up and now there's a 15mm bolt on each gas tank strap and you just want to go ahead and remove those. It does help to remove them if you just add some penetrating oil up here and just go ahead and remove those. Now, with this one, we had some problems. We couldn't actually get the bolt to come out and it ended up breaking off in there, so we're going to use a reciprocating saw and just cut it and really be careful not to cut the tank. Be careful not to cut anything but the bolt. If this doesn't work, or if you don't have a reciprocating saw, you can also use an air hammer, just get it out that way. To remove it, you just turn it and pull it down and out and, for this back one, you actually have to remove the drive shaft if you want to remove this entirely, so you just bend it out of the way.

You just want to lower the jack. Ideally, you're going to want to have your trunk about two feet off the ground to have enough space to do that. You bring the front of it down and then kind of slide it forward to get it out. On the back of it, there's a harness right here and you want to lift up on that tab and disconnect that harness. Then, from the front, up on top of the gas tank, there's another harness. Again, just lift up on the tab and disconnect it and then have someone help and hold the other side of the gas tank, remove that jack stand and if you're lower to the ground because you're using standard jack and jack stands and not the lift, you won't necessarily need two people and you can just move it out carefully and you also want to make sure that this is as close to empty as possible. You just want to work it down and the strap on the back may get in the way, just lift that out of the way and then your tank is free.

Now we're going to reinstall. Put the back end up in. You can't go all the way back. That looks good. Reach up in, find the harness. Reconnect this harness at the top of the fuel tank. Clip in your gas tank strap and replace the bolt. To get the other gas strap in that fell out while you were putting the tank up and in there, you're going to have to remove these four 11mm bolts with an 11mm wrench. Then, you just want to put those brackets and bolts back in just a little bit, so that when you go to remove the drive shaft, it doesn't just go flying off. Take a hammer, hit it a couple of times to loosen it up, then using a pry bar or a large flat blade screwdriver, just pop it out. Once you get it to break free, you can remove those brackets and then pull the drive shaft down and put the gas tank strap back up into place. Once you get it in place, put the drive shaft back in and just use a hammer to tap it back into place and then replace those brackets and the 11mm bolts and tighten them all up. Then, replace the bolt for this gas tank strap and tighten up both of the gas tank strap bolts. Now, you can lower your jack stand and remove it and reconnect this harness up here and reconnect this other harness.

Push your fuel tank filler neck hose back into place and once you get it all pushed in, we're going to just slide that hose clamp up into place and tighten that up. Reconnect the fuel lines and we just push into place and reconnect this line, then replace the cross bar and the four 15mm bolts that hold it in place and tighten them all up.

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 needed for replacement:

    General Tools

  • Reciprocating Saw
  • Hammer
  • Jack Stands
  • Drain Pan
  • Floor Jack

  • Materials, Fluids, and Supplies

  • Rust Penetrant

  • Pliers, Cutters & misc Wrenches

  • Needle nose pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 15mm Socket
  • 7mm Socket

  • Wrenches - Metric

  • 11mm Wrench


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