Installation Procedure

WARNING: This page is about a different variant/trim than selected.

Fig 1: Fuel Tank Insulators

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank insulators.
Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank. Refer to Fuel Sender Assembly Replacement .

Fig 2: View Of Fuel Tank (Cutaway Van Rear Tank)

Courtesy of GENERAL MOTORS CORP.

With the aid of an assistant, position and support the fuel tank.
Raise the fuel tank slightly.
Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
Raise the tank fully.
Install the fuel tank straps (3).

NOTE: Refer to Fastener Notice in Cautions and Notices.

IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.

Install the new attaching bolts (4) to the fuel tank strap.
Tighten: Tighten the bolts to 20.5 N.m (15 lb ft).

Fig 3: Locating Fuel Pipe Connections

Courtesy of GENERAL MOTORS CORP.

Remove the caps from the fuel and EVAP pipes.
Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 4: View Of Fuel Fill Hose (Cutaway Van Rear Tank)

Courtesy of GENERAL MOTORS CORP.

Connect the fuel fill hose to the fuel tank (1).
Tighten: Tighten the fuel fill hose clamp (2) to 2.75 N.m (24 lb in).
Lower the vehicle.
Refill the fuel tank.
Tighten the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks:
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.