Fuel Tank

Complete removal and replacement of the fuel tank on a 2014-2018 Chevrolet Silverado 1500 with 5.3L V8 engine, including fuel system depressurization, tank strap removal, and all fuel line disconnection.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — Use OEM specification
• Fuel tank straps (if corroded) × 2 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Fuel filler neck hose clamp × 1 — Use OEM specification
• EVAP line quick-connect O-rings × 2 — Use OEM specification
• Tank shield hardware (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level, solid ground outdoors or in well-ventilated shop. Set parking brake and place wheel chocks behind rear wheels.
2. Disconnect negative battery cable and isolate terminal to prevent electrical sparks during fuel system work.
3. Verify fuel level is at 1/4 tank or less. If tank is fuller, drive vehicle to consume fuel or use approved fuel transfer pump to remove excess fuel.
4. Position Class B fire extinguisher within immediate reach of work area.
5. Raise vehicle using floor jack and support securely on jack stands rated for vehicle weight. Minimum 24 inches of clearance recommended.
6. Remove rear skid plate/fuel tank shield if equipped by removing mounting bolts.
7. Place drain pan under fuel tank area to catch any fuel spillage.

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse in the underhood fuse block (fuse #87, 20A). Remove the fuel pump fuse. Start the engine and allow it to run until it stalls from fuel starvation. Attempt to restart the engine 2-3 times to ensure all pressure is relieved. Turn ignition to OFF position. Verify zero pressure by connecting fuel pressure gauge to the Schrader valve on the fuel rail and confirming 0 PSI reading.
   ⚠️Do not skip this step. Pressurized fuel will spray when lines are disconnected, creating immediate fire hazard.
2. 2

   Disconnect fuel filler neck
   Locate the fuel filler neck on the driver side rear behind the fuel door. Use a flat blade screwdriver or nut driver to loosen the filler neck hose clamp at the tank connection point. Carefully twist and pull the rubber filler neck hose off the tank inlet pipe. Some residual fuel will drain - catch with towels or drain pan.
   ⚠Filler neck hose may be stiff from age. Do not use excessive force that could damage tank inlet pipe threads.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
3. 3

   Disconnect EVAP and vent lines
   Locate the EVAP canister vent line and purge line quick-connect fittings on the top front of the fuel tank. Using appropriate fuel line disconnect tool, press the release tabs and carefully pull the lines straight off the tank connectors. Cap or plug the lines to prevent dirt entry. Inspect O-rings and replace if damaged.
   ⚠Quick-connect fittings require specific release technique. Forcing without proper tool will break the connector tabs.
4. 4

   Disconnect fuel supply and return lines
   Locate the fuel supply line and return line quick-connect fittings on the top front of the tank near the fuel pump module. Place towels underneath as residual fuel will drip. Use appropriate size fuel line disconnect tool to release each fitting by pressing release tabs while pulling line straight back. Note routing and orientation for reassembly. Inspect O-rings and mark for replacement.
   ⚠️Even with pressure relieved, residual fuel remains in lines. Avoid skin contact and have towels ready.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
5. 5

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the tank (usually has a gray or black locking tab). Press the locking tab release and disconnect the electrical connector. If equipped with fuel level sensor separate connector, disconnect it as well. Secure connectors away from tank area.
   ℹ️Take a photo of connector orientation before disconnection to aid reassembly.
6. 6

   Position transmission jack under tank
   Position transmission jack or dedicated fuel tank support stand under the center of the fuel tank. Raise jack until it just contacts the tank bottom with light pressure - do NOT lift the tank yet. Adjust position to ensure tank is balanced and centered on jack saddle. Use a strap or ratchet strap to secure tank to jack if available.
   ⚠️Tank must be properly balanced on jack. An off-center tank can fall when straps are released, causing crush injury.
7. 7

   Remove fuel tank strap bolts
   Locate the two fuel tank strap bolts at the rear of each strap where they attach to the frame. Using appropriate socket (typically 15mm), remove the rear strap bolt from the passenger side strap first, allowing that strap to pivot down. Then remove the rear bolt from the driver side strap. The tank is now held only by the jack - straps will hang loose.
   ⚠️Straps are under tension. As you loosen the second bolt, ensure jack is securely supporting tank weight.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
8. 8

   Lower and remove fuel tank
   With all connections and straps removed, slowly and carefully lower the transmission jack to lower the tank. Monitor all around the tank as you lower to ensure no forgotten hoses, wires, or lines are still connected. Lower tank approximately 12-18 inches, then carefully slide the tank rearward and toward the driver side to clear the frame and exhaust components. Continue lowering to ground level. Have an assistant help guide the tank if possible.
   ⚠️Tank may still contain several gallons of fuel weighing 50+ lbs. Lower slowly and maintain control at all times.
   ⚠Watch for exhaust system components and brake lines as you maneuver tank out from under vehicle.
9. 9

   Remove tank shield and inspect
   With tank on ground, remove the fuel tank shield (if still attached) by removing the shield mounting screws. Inspect tank shield for damage or excessive corrosion - replace if compromised. Inspect the fuel tank itself for dents, corrosion, or damage. Inspect tank straps for cracks, rust, or deformation - replace if compromised. Check all rubber isolators and grommets.
   Torque spec

   Cover Screws14 Nm (10 lb-ft)
10. 10

    Install replacement tank or prepare for reinstallation
    If installing a new tank, transfer the fuel pump module, fuel level sensor, and any other components from old tank to new tank according to separate fuel pump replacement procedure. If reusing tank, clean exterior with degreaser and wire brush, inspect all mounting points. Install new O-rings on all fuel line fittings - do NOT reuse old O-rings. Lubricate new O-rings lightly with clean engine oil.
    ⚠New O-rings are critical for preventing fuel leaks. Using old O-rings will result in dangerous fuel seepage.
    Torque spec

    Pump Mounting16 Nm (12 lb-ft)
11. 11

    Position tank for installation
    Place the fuel tank (with new or transferred components) onto the transmission jack. Secure with strap if available. Carefully raise the tank while guiding it into position between the frame rails, angling as needed to clear exhaust and other components. Align tank so that the fuel pump module is accessible from above and fuel filler neck inlet is aligned toward filler neck hose. Raise until tank is approximately 1 inch below final mounting position.
    ⚠Take your time during positioning. Rushing can result in damaged fuel lines or electrical connectors being pinched.
12. 12

    Install fuel tank straps
    Swing both fuel tank straps up into position over the tank. Align the front loops of the straps with the frame mounting points. Install but do not fully tighten the rear strap bolts on both sides - leave them finger tight. Ensure straps are not twisted and are properly seated in tank strap channels. Raise jack to bring tank to final position where strap holes align perfectly with frame threads.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
13. 13

    Torque tank strap bolts
    Using torque wrench, tighten both fuel tank strap bolts alternately and evenly to 35 Nm (26 lb-ft). Start with passenger side, then driver side, then recheck both. Straps should be evenly tensioned and tank should be firmly secured without excessive deflection. Verify tank is not tilted or askew.
    ⚠Over-torquing strap bolts can deform tank. Under-torquing allows tank movement and potential line damage.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
14. 14

    Reconnect electrical connectors
    Reconnect the fuel pump module electrical connector, ensuring the locking tab clicks into place securely. Reconnect fuel level sensor connector if separate. Gently tug on connectors to verify they are fully locked. Ensure wiring is routed away from sharp edges and heat sources.
    ℹ️Verify connector orientation matches your reference photo from disassembly.
15. 15

    Reconnect fuel lines
    Reconnect the fuel supply and return lines to the tank fittings. Push each line straight onto the fitting until you hear and feel a distinct click. Gently pull on each line to verify it is locked - it should not pull free. Verify new O-rings are in place and not pinched.
    ⚠️Incompletely connected fuel lines will leak under pressure, creating fire hazard. Each line must click and lock positively.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
16. 16

    Reconnect EVAP lines and filler neck
    Reconnect EVAP vent and purge lines to tank fittings - each should click into place. Slide the fuel filler neck hose onto the tank inlet pipe, ensuring it is fully seated. Install new hose clamp and torque to 4.0 Nm (3 lb-ft). Ensure clamp is positioned over the reinforced section of the hose.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
17. 17

    Reinstall tank shield
    If equipped, position fuel tank shield and install mounting screws. Torque shield mounting hardware to specification. Ensure shield is not contacting any fuel lines or electrical connectors and has proper clearance.
    Torque spec

    Cover Screws14 Nm (10 lb-ft)

    Bracket Bolts25 Nm (19 lb-ft)

Reassembly

1. Reinstall rear skid plate or underbody shield panels if removed.
2. Reconnect negative battery cable to battery terminal.
3. Reinstall fuel pump fuse (fuse #87, 20A) in underhood fuse block.
4. Lower vehicle carefully from jack stands.

Verification

• Turn ignition key to ON position (do not start engine). Listen for fuel pump to run for 2-3 seconds, pressurizing the system. Cycle ignition OFF then ON 3-4 times to build full fuel pressure.
• Perform complete visual inspection under vehicle for fuel leaks at all connection points: fuel lines, EVAP lines, filler neck, and fuel pump module. Look for wet spots or dripping fuel.
• Start engine and allow to idle. Monitor fuel pressure with scan tool or fuel pressure gauge - should read 55-62 PSI. Watch for pressure drop indicating leak.
• With engine running, have assistant inspect under vehicle again for any fuel leaks. Check all connections, especially at tank fittings and fuel line quick-connects.
• Rev engine to 2000 RPM several times and verify no fuel odor in cabin or around vehicle.
• Test drive vehicle and monitor for proper fuel system operation, no fuel odor, and no check engine light.
• After test drive, perform final inspection under vehicle for any delayed leaks or seepage at fittings.

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