1993 Chevrolet Suburban Fuel Tank Removal

The 1993 Chevy Suburban is powered by a small-block 5.7-liter V-8 engine and an automatic transmission. The Suburban was not known for excellent gas mileage because it only achieved a rating of 17 mpg on the highway, and a jaw dropping 13 mpg in the city. With such low mileage, Chevy installed a 42-gallon fuel tank. With such a large tank, draining as much fuel as possible before removing the fuel tank is imperative for safety reasons. The fuel tank is located at the rear of the Suburban, just behind the rear axle.

Instructions

Removal

1

Park the vehicle on a flat surface and set the parking brake. Place wheel chocks around the front wheels.

2

Lift the vehicle hood and support it with the hood prop rod. Remove the negative battery cable with the socket and ratchet.

3

Lift the rear of the vehicle with the floor jack and place the jack stands under the rear frame rails. Lower the floor jack until the vehicle rests securely on the jack stands. Shake the vehicle to ensure it is positioned safely and will not move.

4

Remove the gas cap to relieve the vapor pressure in the fuel tank. Place the suction tube of the siphon pump through the fuel fill neck, and siphon as much fuel from the tank into the gas cans as possible.

5

Remove the six bolts holding the fuel tank shield around the gas tank with the socket and ratchet. Remove the fuel tank shield and set it aside.

6

Remove the screw clamps from around the fuel filler neck and vent hose and the fuel tank with a screwdriver. Disconnect the fuel filler neck and vent hose from the gas tank.

7

Position the floor jack under the fuel tank and place the 3-foot-long block of wood on the jack arm. Lift the floor jack until the wood contacts the fuel tank. Remove the four bolts holding both fuel tank straps to the vehicle with the socket and ratchet. Remove the fuel tank straps.

8

Lower the floor jack just enough to provide access to the top of the fuel tank.

9

Disconnect the body ground strap from the fuel tank with the socket and ratchet. Turn the fuel sending line and return line fittings counterclockwise with the line wrench set and separate them from the fuel pump. Use a line wrench on the fuel pump fitting to prevent damage to the fuel pump line. Disconnect the vehicle wiring harness from the fuel pump pigtail.

10

Support the tank with one hand and lower the floor jack as low as it will go. Slide the fuel pump off the wood block and floor jack and onto the cardboard. Slide the fuel tank from under the vehicle.

Installation

11

Slide the fuel tank under the vehicle. Have a helper assist in lifting the fuel tank onto the wood block and jack arm. Begin to lift the floor jack and guide the fuel tank into position.

12

Connect the fuel pump sending and return lines and tighten them with the line wrench. Attach the fuel pump electrical connector. Put the body ground strap in place and install the ground strap bolt. Tighten the ground strap bolt with the socket and ratchet.

13

Lift the fuel pump until it is in position. Lift the fuel tank support straps into position and install the fuel tank strap bolts. Tighten the fuel tank strap bolts with the socket and ratchet. Lower the floor jack and remove the wood block. Remove the floor jack from under the vehicle.

14

Install the fuel filler neck and filler neck vent hose onto the fuel tank nipples. Tighten the screw clamps with a screwdriver.

15

Hold the fuel tank shield in position and tighten the six mounting bolts with the socket and ratchet.

16

Lift the rear of the vehicle off the jack stands with the floor jack. Remove the jack stands from under the vehicle. Lower the vehicle to the ground and remove the floor jack. Pour any fuel that was drained into the gas can through the fuel neck and into the gas tank. Install the gas cap until it clicks three times.

17

Install the negative battery cable onto the battery and tighten the terminal bolt with the socket and ratchet. Turn the ignition key to the "On" position for 10 seconds, and turn it off. Repeat the on and off process three times to pressurize the fuel system.

18

Start the vehicle and inspect for any fuel leaks. Repair them before driving the vehicle.