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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 977 (Engine Controls - 6.6L (LLY) (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Pickup) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Feed And Return Lines At Sending Unit (Pickup)
    GM1306338Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Install and connect the fuel feed (1) and return (2) lines to the sending unit and retaining clips. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    3. Fig 2: View Of Fuel Tank Straps (Pickup)
    GM1228093Courtesy of GENERAL MOTORS CORP.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank until the sending unit electrical connection can be made.
  5. Connect the sending unit electrical connector.
  6. Install the fuel tank.
  7. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the fuel tank strap bolts.

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

  9. Remove the jack from under the fuel tank.
    10. Fig 3: View Of Fuel Feed And Return Lines At Fuel Tank (Pickup)
    GM1228124Courtesy of GENERAL MOTORS CORP.
  10. Remove the caps from the fuel lines.
  11. Connect the fuel feed and return lines to the fuel tank. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 4: Fuel Tank Shield Bolts (Pickup)
    GM626413Courtesy of GENERAL MOTORS CORP.
  12. If necessary, install the fuel tank shield.
  13. If necessary, install the fuel tank shield bolts.

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

  14. Install the fuel system cooler. Refer to Fuel System Cooler Replacement (Pickup)  or Fuel System Cooler Replacement (Cab/Chassis) .
    15. Fig 5: Fuel Fill Pipe Assembly
    GM1378752Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel tank fill pipe and vent hose to the fuel tank.
  16. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

  17. Tighten the fuel tank vent hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 2.5 N.m (22 lb in).

    18. Fig 6: Fuel Tank Ground Strap Bolt
    GM1238144Courtesy of GENERAL MOTORS CORP.
  18. Position the fuel tank ground strap (3).
  19. Install the fuel tank ground strap bolt (1).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    20. Fig 7: Rear Axle Vent Hose On The Fuel Fill Pipe
    GM1238161Courtesy of GENERAL MOTORS CORP.
  20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  21. Lower the vehicle.
    22. Fig 8: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  22. Install the fuel tank filler housing.
  23. Install the fuel tank filler housing to fuel tank fill pipe screws.

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

    24. Fig 9: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  24. Install the fuel tank filler housing to body screws (1), and retainer (2).

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

  25. Fill the fuel tank.
  26. Install the fuel fill cap.
  27. 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.
  28. Prime the fuel system. Refer to Fuel System Priming .
  29. Start the engine. If the engine stalls, repeat the above step.
  30. Once the engine starts, inspect for fuel leaks.
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