Here's a general outline. Always consult a repair manual specific to your 1994 Chevrolet Suburban for detailed instructions, torque specifications, and diagrams. Different models may have slight variations.
Safety First:
* Disconnect the battery's negative terminal. This prevents accidental sparks.
* Ventilate the area. Gasoline fumes are highly flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher nearby.
* Support the vehicle properly. Use jack stands, never rely solely on a jack.
Steps (General Outline – Refer to your repair manual for specifics):
1. Drain the fuel tank: This is crucial. Use a siphon pump to remove as much fuel as possible. Dispose of the fuel properly according to local regulations.
2. Disconnect the fuel lines: This is critical. There will be at least two lines: a fuel supply line and a fuel return line. They'll likely be connected with quick-disconnect fittings or clamps. Mark which line goes where to avoid confusion during reassembly. Use appropriately sized wrenches to loosen clamps if necessary. You may need to relieve pressure in the fuel system; consult your repair manual for this procedure. Be prepared for a small amount of fuel spillage. Use absorbent rags to clean up any spills immediately.
3. Disconnect the electrical connections: Locate and disconnect the fuel level sender wire. Again, mark the connections for easy reassembly.
4. Remove the filler neck: This may involve removing bolts or clamps securing the filler neck to the body of the vehicle. Your repair manual will show you exactly where the fasteners are located.
5. Disconnect the vent line: Locate and disconnect the vent line from the tank.
6. Remove the fuel tank straps/holders: These straps hold the tank in place. You'll likely need to use wrenches or sockets to remove the bolts or clamps securing the straps.
7. Lower the tank: Carefully lower the fuel tank. It will likely be heavy, so you may need a helper. Be mindful of any obstructions or wires that could get in the way.
8. Complete the repair or replacement: Once the tank is removed, you can proceed with your repair or replacement.
9. Reassembly: Reassemble everything in reverse order, ensuring all connections are secure and tight.
10. Check for leaks: After reassembly, check all fuel lines and connections for leaks. Start the vehicle and monitor for any leaks.
Important Considerations:
* Rust and corrosion: The bolts holding the tank and straps might be rusted and difficult to remove. Use penetrating oil and patience. If a bolt breaks, you might need to drill it out.
* Accessibility: Access to the fuel tank may be limited. You might need to remove other components (such as the exhaust system or parts of the undercarriage) to gain better access.
* Repair Manual: A repair manual specific to your 1994 Chevrolet Suburban is essential for detailed instructions, diagrams, and torque specifications.
This is a complex procedure. If you are not comfortable performing this repair yourself, it is strongly recommended that you take your vehicle to a qualified mechanic. Improper handling can lead to serious injury or damage.
