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Help a newbie replace fuel tank in an '04 Express

Old Apr 10, 2026 | 12:25 PM
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ScaldedDog's Avatar
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Default Help a newbie replace fuel tank in an '04 Express

Hi all. First post. A thief drilled through the tank of my church's '04 Express van, and I'm replacing it with one from Autozone. I've done this sort of thing other vehicles, but have never even seen one of these, or worked on any Chevy. So, I have a few questions I'm hoping you guys will answer before I start on this thing:

1) Are there proprietary fuel connection tools required to disconnect lines? (My '01 PSD Excursion has what I think are Ford-specific connectors, which is why I ask)
2) Do I have to worry about breaking connectors on top of the tank as I lower it, or is there enough slack that I'll be able to see and reach them as the tank comes down?
3) It appears the charcoal cannister and something else (fuel filter? pump?) are attached to the front of the tank. Are there any tips or tricks to getting these loose without breaking any of the plastic fasteners?

I crawled under it yesterday, but my old eyes were too close to things for me to see details. If you guys can help, I'd sure appreciate it. I saw this thread (Fuel tank vents and evap system line swap help - Chevrolet Forum - Chevy Enthusiasts Forums), but if there are other resources I should see, please point me to them.

Thanks!!

Mark
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Old Apr 10, 2026 | 1:59 PM
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I haven't done it, a few on here I think have.
https://charm.li/Chevrolet/2004/Expr...argo%20Van%29/
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Old Apr 10, 2026 | 5:23 PM
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Originally Posted by Triaged
I haven't done it, a few on here I think have.
https://charm.li/Chevrolet/2004/Expr...argo%20Van%29/
You rock, sir.

Mark
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