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Fuel Tank (Cab & Chassis): Installation

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the caps from the fuel and EVAP pipes. With the aid of an assistant, place the fuel tank on the jack. Raise the fuel tank. Install the fuel tank straps.
  2. Install the fuel tank strap bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  3. Remove the jack from under the fuel tank. Install the fuel tank shield. Install the fuel tank shield bolts and tighten to specification. Lower the vehicle.
  4. Connect the fuel feed/return pipes to the fuel tank pipes. See FUEL LINE DISCONNECT FITTINGS .
  5. Reconnect fuel tank sending unit and fuel pressure sensor harness connectors. Install the fuel fill pipe and vent hose to the tank. Tighten the fuel fill and vent hose clamps at the tank to specification.
  6. Connect the fuel feed and pressure balance rear pipes, if required. See FUEL LINE DISCONNECT FITTINGS . Install the fuel fill cap. Connect the negative battery cable. Tighten battery cable bolt to specification.
  7. Use the following procedure in order to inspect for leaks: Turn the ignition on, with the engine off, for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on, with the engine off. Inspect for fuel leaks.
  8. Install engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS.
Fig 1: Removing/Installing Fuel Tank Shield (Cab & Chassis; Front)
G00156244Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing/Installing Fuel Tank Shield (Cab & Chassis; Rear)
G00156245Courtesy of GENERAL MOTORS CORP.


  1. With the aid of an assistant, place the fuel tank on the jack. Raise the fuel tank. Install the fuel tank straps. Install the fuel tank strap bolts and tighten the bolts to specification. See TORQUE SPECIFICATIONS .
  2. Remove the jack from under the fuel tank. Install the fuel tank shield. Install the fuel tank shield bolts and tighten to specification. Lower the vehicle.
  3. Connect the fuel feed/return pipes to the sending unit. See FUEL LINE DISCONNECT FITTINGS . Connect the fuel tank pressure sensor electrical connector.
  4. Install the fuel fill pipe and vent hose to the tank. Tighten the fuel fill and vent hose clamps to specification. Fill the fuel tank. Install the fuel fill cap. Connect the negative battery cable. Tighten battery cable bolt to specification.
  5. Use the following procedure in order to inspect for leaks: Turn the ignition on, with the engine off, for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on, with the engine OFF. Inspect for fuel leaks.
  6. Install engine sight shield. See ENGINE SIGHT SHIELD  under MISCELLANEOUS.
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