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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 973 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Pickup - 5.3L (L59) Engine) >> Installation Procedure

Installation Procedure

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  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine) .
  2. If necessary, install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
  3. If necessary, install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.
    4. Fig 1: EVAP Pipe, Fuel Feed And Return Pipes
    GM815641Courtesy of GENERAL MOTORS CORP.
  4. With the aid of an assistant, place the fuel tank on the jack.
  5. Raise the fuel tank until the electrical connections can be made.
  6. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
    7. Fig 2: Fuel Pressure Sensor Electrical Connectors (Pickup - 5.3L (L59))
    GM878152Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel sending unit CPA retainer.
  8. Completely raise the fuel tank.
  9. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    11. Fig 3: Fuel Tank, Strap & Bolts (Pickup - 5.3L (L59))
    GM300138Courtesy of GENERAL MOTORS CORP.
  11. Remove the adjustable jack from under the fuel tank.
  12. Remove the caps from the fuel lines.
  13. Connect the fuel feed and return line quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Install the fuel feed and return lines to the clip on the fuel tank.
    15. Fig 4: Fuel Feed And Return Line Quick Connect Fittings
    GM878130Courtesy of GENERAL MOTORS CORP.
  15. If equipped, install the fuel tank shield.
  16. If equipped, install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

    17. Fig 5: Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  17. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement (Pickup)  or Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)  or Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis) .
  18. Install the fuel tank fill pipe. Refer to Filler Tube Replacement (Pickup)  or Filler Tube Replacement (Pickup - 5.3L (L59) Engine)  or Filler Tube Replacement (1500 Crew Cab)  or Filler Tube Replacement (Cab/Chassis - Front)  or Filler Tube Replacement (Cab/Chassis - Rear) .
  19. Refill the fuel tank.
  20. Install the fuel cap.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  22. Perform the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
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