Katerina Swanson
Removing the fuel tank from a 2003 GMC Sierra can be a challenging task. Before starting, it is recommended to run the tank as empty as possible to make the job easier and reduce the risk of fuel spills. The process typically involves unbolting various components, such as the filler neck, grounding strap, tank shield, and tank straps, and then slowly lowering the tank using a jack. Some people also suggest removing the bed of the truck to provide better access to the fuel tank and make the process less cumbersome. It is important to take safety precautions and carefully follow the correct procedure to avoid any damage to the vehicle or injury to oneself.
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What You'll Learn
Removing fuel from the tank
Firstly, it is highly recommended to run your tank to almost empty before initiating the fuel tank removal process. This makes the job significantly easier and safer. If you have a significant amount of fuel in the tank, consider using a pump to remove as much fuel as possible. You can also try loosening the fuel filler cap and disconnecting the fuel fill hose from the fuel fill pipe to drain the fuel.
Once you've ensured that the fuel level is low, you can proceed with the next steps. If your vehicle has a skid plate, you will need to remove it. Be cautious of any rusty components, as they can be challenging to work with. Spray a rust breaker product on the bolts a day before you intend to remove them, and again before attempting to loosen them.
Now, you can release the rubber hose from the tank inlet at the filler neck. It is important to stuff a rag into the inlet to prevent any debris from falling into the tank. At this point, you should also remove the ground wire from the fuel pump that is attached to the frame rail. This step is not mandatory but can make the process easier and reduce the risk of breaking certain components.
Next, you can start to slowly lower the tank using a floor jack. Some vehicles may require you to remove or tilt the bed for better access. If you need to remove the bed, simply remove the bolts and secure the bed in a tilted position using jack stands and blocks of wood.
As you lower the tank, you will need to disconnect the fuel lines and hoses. Depending on your vehicle, you may have one to three hoses connected to the sender. Carefully disconnect these hoses and any wires attached to the sender.
By following these steps, you will effectively remove the fuel from the tank and prepare for the safe removal of the fuel tank itself. Remember to always take necessary safety precautions and refer to vehicle-specific instructions for a more detailed guide.
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Disconnecting wires and hoses
Firstly, remove the filler hose and vent line from the tank. This involves removing the bolts holding the filler neck with a 7mm socket. You may also need to remove the bolts on the filler hose with a 10mm socket.
Next, disconnect the ground wire from the fuel pump that is attached to the frame rail. This ground wire may also be from the tank to the frame, or from the sending unit to the frame.
Depending on your sender, you may have one to three hoses to disconnect. These hoses are connected to the fuel pump and gas lines. To disconnect them, simply squeeze the ends and pull them off.
It is also important to note that you may need to deal with rust on the lock ring of the fuel pump module. Cleaning the area of any foreign debris is crucial before removing the lock ring.
Additionally, some users have mentioned the need to cut the harness and splice in a new connector. This step may vary depending on your specific model and situation.
Finally, it is recommended to use a floor jack to slowly lower the tank. This will provide easier access to the wires and hoses. Some users have also suggested using a motorcycle jack for lowering and raising the tank.
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Using a jack to lower the tank
It is recommended to run your tank to almost empty to make the job of removing the fuel tank easier. Before you start to lower the tank, remove the two lines (top and bottom) on the piece directly in front of the tank.
Now you are ready to start slowly lowering the tank with a jack. A motorcycle jack is extremely handy for this purpose. You can also use a floor jack, which can be raised until it touches the tank bracket. Lower the tank until you can reach and disconnect the two lines running from the top of your fuel pump and into the gas lines.
If you have a crazy lift kit, find a way to support the tank and lower it slowly. You can also use a floor jack and a piece of plywood to lower the tank. The plywood keeps the tank from being damaged by the jack and gives you a more stable support.
If you are removing a rusty fuel tank, be careful not to jostle the rusty fuel line as it may crack and spray fuel everywhere. It is also recommended to clean the area of any foreign debris before removing the lock ring, as there will be rust all over the place.
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Removing the tank shield and straps
To remove the tank shield and straps, you will need a 13mm socket to remove the bolts holding the tank shield, and a 15mm socket to remove the tank straps.
First, you should ensure your tank is almost empty, as this will make the job much easier. You should also chock the wheels for safety. If your GMC Sierra has a skid plate, you will need to remove it. Next, release the rubber hose from the tank inlet at the filler neck and stuff a rag into the tank inlet to prevent debris from entering.
Now, you can remove the ground wire from the fuel pump that is attached to the frame rail. This step is not essential, but it will make the process easier and reduce the risk of breaking something.
You can then remove the tank shield using the 13mm socket. Finally, use the 15mm socket to remove the tank straps.
Some people recommend using a jack to lower the tank slowly and safely once the straps are removed. You can use a floor jack, or a motorcycle jack if you have one.
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Replacing the fuel pump
The fuel pump is responsible for delivering gasoline from the fuel tank to the fuel injectors, maintaining the flow the engine needs to function. The pump delivers fuel at a high enough pressure to keep the engine running smoothly.
Before starting, it is recommended to run your tank almost empty, as this will make the job easier. You will need a 7mm socket for the 3 bolts that hold the filler neck, a 10mm socket for the grounding strap attached to the filler neck and frame, a 13mm socket to remove the 4 bolts that hold the tank shield, a 15mm socket to remove the 2 tank straps, a flat-head screwdriver, a jack, and jack stands.
First, disconnect the battery to reduce the chance of a fire. Next, jack up the rear of the truck and place a jack stand underneath to create space to lower the fuel tank. Now, use an additional jack to support the fuel tank and detach the fuel lines going to the tank. Before lowering the tank, remove the two lines (top and bottom) on the piece directly in front of the tank. Slowly lower the tank until you can reach the two lines running from the fuel pump to the gas lines, and disconnect them.
Open the fuel pump hatch on top of the tank and disconnect the power cables and fuel lines from the pump. Remove the old pump and set the replacement in. Connect the wires and lines, reinstall the fuel tank, and attach the fuel lines to complete the replacement.
It is recommended to replace the fuel filters at the same time as the fuel pump. Additionally, if your truck has a bed, it may be easier to remove the bed instead of lowering the fuel tank.
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Frequently asked questions
There are a few methods to remove the fuel tank from your 03 Sierra. The first method is to remove the bed of your truck. This is considered the easier method by some, as it allows you to replace the tank straps and access the top of the tank. The second method is the "remove/tilt bed" method. This method involves removing the bolts on the driver's side and loosening the bolts on the passenger side, then lifting the bed until you have enough room to access the tank. The third method is the "drop the tank" method. This method involves draining the fuel from the tank, removing the skid plate, and then slowly lowering the tank and disconnecting the necessary hoses and wires.
You will need a variety of sockets and screwdrivers, including a 7mm socket, a 10mm socket, a flat-head screwdriver, and a 13mm socket. You will also need a jack and jack stands, preferably a motorcycle jack. A floor jack and a piece of plywood can also be used to lower the tank.
It is recommended to remove as much fuel as possible before dropping the tank. This can be done by using a pump to drain the fuel or by disconnecting the fuel fill hose and using a hand or air-operated pump device.
If the tank strap bolts are rusted, you can use a rust breaker like PB Blaster to spray the bolts a day before you intend to remove them. You can also try to cut a hole in the bed to access the pump, but this should only be done if there are no other options.
