Here's a general outline. Consult a repair manual specific to your 1994 Suburban's year, model, and engine for precise details and torque specifications. Different Suburbans might have slight variations.
Safety First!
* Disconnect the battery's negative terminal. This is crucial to prevent sparks.
* Ventilate the area extremely well. Work in an open space with good air circulation. Gasoline fumes are highly flammable and can be lethal.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available. A class B or ABC extinguisher is best.
* Use tools appropriate for the job. Don't use damaged or makeshift tools.
Procedure:
1. Prepare the Vehicle: Park the Suburban on a level surface and engage the parking brake.
2. Reduce Fuel Level: Ideally, almost completely empty the fuel tank. This significantly reduces the risk of spills and makes the tank lighter to handle.
3. Disconnect Fuel Lines:
* Locate the fuel lines: These connect to the tank's sending unit. They will likely be metal or flexible rubber lines.
* Use appropriate wrenches or pliers to loosen the clamps securing the lines.
* Carefully disconnect the lines. Have rags or containers ready to absorb any spilled fuel. You might need to relieve pressure within the fuel lines by opening the fuel cap slightly before disconnecting them. Consult your repair manual to see if there are special procedures.
4. Disconnect the Fuel Sender: This unit usually has electrical connections for the fuel gauge and sending unit. Disconnect these electrical connectors carefully.
5. Disconnect the Vent Line: The tank vent line prevents pressure buildup. Locate and disconnect this line.
6. Disconnect the Fuel Tank Straps: There are usually several straps securing the tank to the vehicle's frame. These are typically bolts or clamps. Remove these securely.
7. Lower the Tank: The tank is usually relatively heavy, even when nearly empty. You may need a helper.
* Carefully lower the tank. Be aware of any obstructions or other parts that might be in the way.
* Use jack stands or a suitable support to hold the tank as you remove the straps.
8. Remove the Tank: Once the straps are off, carefully maneuver the tank out from its location. You may need to use straps or a hoist to lift the tank. The tank may be difficult to maneuver due to its shape and size.
After Removal:
* Properly dispose of any spilled fuel. Do not pour it on the ground; it's dangerous to the environment.
* Inspect the fuel tank and lines for damage. Replace any damaged components.
Important Notes:
* This is a simplified overview. Consult your vehicle's repair manual for specific instructions and diagrams. The location and type of fasteners may vary slightly.
* If you're not comfortable performing this task, take your Suburban to a qualified mechanic. Working with fuel systems is potentially dangerous and requires specific knowledge and tools.
* Always double-check your work before reassembly. Ensure all fuel lines, electrical connections, and straps are properly connected.
Remember, safety is paramount. If you are unsure about any step, seek professional help. Improper fuel handling can lead to serious injury or death.
