How to Remove a Gas Tank in a 1993 GMC Vandura

The 1993 GMC Vandura came in four trim levels, including G1500, G1500 Extended, G2500 and G2500 Extended. The base level Vandura G1500 came standard with a 155-horsepower, 4.3-liter V-6 engine and electronic fuel injection. Replacing the fuel tank in this full-size van requires great care, as even the smallest spark can ignite the fuel vapors in the tank. This is why you must disconnect the negative battery cable before removing the fuel tank.

Instructions

Removal

1

Open the hood and loosen the negative battery cable end using a combination wrench. Pull the negative cable end from the battery and set it aside to prevent accidental reconnection. Remove the gas cap to remove pressure from the fuel system.

2

Insert a fuel siphon with a flexible hose into the fuel filler hole and position the siphons drain hose into an approved fuel-storage container. Siphon as much fuel as you can from the tank.

3

Raise the rear of the van with a floor jack and slide jack stands under the vans frame rails.

4

Slide under the van and loosen the hose clamps retaining the fuel filler hose and the fuel tank vent line, using a flat-head screwdriver.

5

Slide the floor jack directly under the center of the gas tank. Place a 2-foot-long piece of 2-by-4 inch wood across the jacks plate. Raise the jack until it contacts the fuel tank. Do not apply any upward pressure on the tank.

6

Remove the nut and bolt from each fuel tank strap, using a ratchet and socket, and remove the fuel tank straps. Lower the tank just enough to gain access to the fuel pump wiring and hoses.

7

Unplug the ground strap and wiring harness from the fuel pump assembly. Label the fuel pump hoses using a permanent marker and masking tape. Loosen the hose clamps securing the fuel hoses to the fuel pump, using a flat-head screwdriver, and pull the hoses from the fuel pump. Lower the jack to remove the fuel tank.

Fuel Pump Transfer

8

Remove the locking ring from the top of the fuel pump by turning it counterclockwise with a fuel sending unit wrench, GM tool No. J-36608. Pull the fuel pump from the fuel tank.

9

Slide the fuel pump into the new fuel tank and rotate it until it is in the exact position it was before you removed it from the old tank.

10

Set the locking ring around the top of the fuel pump and rotate it clockwise with the fuel sending unit wrench to lock the fuel pump into place.

11

Pour any remaining fuel in the old tank into an approved fuel-storage container, using a funnel, via the fuel filler hose inlet.

Installation

12

Balance the new fuel tank on the floor jack with the 2-by-4 inch piece of wood. Raise the fuel tank into its cutout in the underside of the van, leaving three inches of room to reconnect the fuel pump.

13

Press the hoses onto their respective outlets on the fuel pump and tighten the hose clamps with a flat-head screwdriver. Remove the labels from the fuel lines. Plug the ground strap and fuel pump wiring harness into their receptacles on the fuel pump.

14

Raise the tank the rest of the way into its cutout, making certain not to apply any upward force once it is in place. Reinstall the straps around the fuel tank and guide the holes on the outer part of the straps over their mounting studs.

15

Hand-thread the nuts and bolts to retain the fuel tank straps. Tighten the fuel tank strap nuts to 10 foot-pounds using a torque wrench and socket. Tighten the fuel tank strap bolts to 85 inch-pounds using an inch-pound torque wrench and socket.

16

Press the vent hose and filler hose onto their inlets on the new fuel tank and tighten their hose clamps with a flat-head screwdriver.

17

Lower the jack from the fuel tank and remove the wood from the jacks plate. Raise the rear of the van off the jack stands, using a floor jack, and remove the jack stands. Lower the Vandura to the ground.

18

Fill the new tank with the fuel in the fuel-storage containers.

19

Reconnect the negative battery cable and tighten it with a combination wrench. Turn the ignition to the Run position and wait about 10 seconds. Turn the vehicle off, then to the Run position again. Check under the fuel tank for leaks. If no leaks exist, start the van and verify that it runs correctly.