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Home >> Chevrolet >> 2004 >> Avalanche 2500 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System - 4.8L, 5.3L & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Single Tank w/5.3L (L59) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Fuel Sender & Fuel Pressure Sensor Electrical Connectors (Single Tank w/5.3L (L59) Engine)
    GM855750Courtesy of GENERAL MOTORS CORP.
  1. If necessary, install the fuel sending unit. Refer to Fuel Sender Assembly Replacement (4.8L and 5.3L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Front)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Rear) .
  2. Connect the fuel feed and return pipes to the fuel sending unit and the retaining clips.
  3. Place the fuel tank onto a suitable jack.
  4. With the aid of an assistant, partially raise the fuel tank.
  5. Connect the fuel sender and fuel pressure sensor electrical connectors (2).
  6. Install the CPA retainer.
    7. Fig 2: View Of Sending Unit Shield
    GM858234Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. If equipped, install the sending unit shield.
  8. If equipped, install the sending unit shield nuts.

    Tighten:  Tighten the nuts to 10 N.m (89 lb in).

    9. Fig 3: View Of Fuel Tank & Straps (Single Tank w/5.3L (L59) Engine)
    GM855751Courtesy of GENERAL MOTORS CORP.
  9. With the aid of an assistant, completely raise the fuel tank.
  10. Install the fuel tank straps.
  11. Install the fuel tank strap bolts.

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

  12. Remove the adjustable jack from the fuel tank.
  13. Connect the vent hose and fill hose to the tank.
  14. Tighten the vent hose and fill hose clamps at the tank.

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

    15. Fig 4: View Of EVAP Canister Vent Pipe & Clips
    GM855747Courtesy of GENERAL MOTORS CORP.
  15. Connect the EVAP vent pipe to the fuel tank clips (6, 7).
    16. Fig 5: View Of Chassis Fuel Pipe & Fuel Tank Pipe
    GM855745Courtesy of GENERAL MOTORS CORP.
  16. Remove the caps from the fuel and EVAP pipes.
  17. Connect the chassis fuel pipes (4) to the fuel tank pipes (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  18. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement (1500 Series)  or Evaporative Emission (EVAP) Canister Replacement (1500 Series - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Replacement (2500 Series) .
  19. Lower the vehicle.
  20. Refill the fuel tank.
  21. Install the fuel fill cap.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  23. Use 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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