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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1142 (Engine Controls - 6.0L - Alternative Fuels (Introduction)) >> Repair Instructions >> Fuel Tank Bracket and Mounting Replacement (Cab/Chassis) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the CNG fuel tank mounting plate onto the vehicle.
    2. Fig 1: Locating Tank Mounting Plate-To-Frame Bolts and Nuts
    GM1203085Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the tank mounting plate to the vehicle frame with new bolts and nuts (1, 2).

    Tighten:  Tighten the nuts to 110 N.m (81 lb ft).

    3. Fig 2: Identifying High Pressure Regulator (HPR) Components
    GM757008Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not hold the HPR at the cover hex flange. As required, wedge a wrench between the HPR and the tank frame in order to keep the HPR from spinning in the bracket.
  3. Install the HPR assembly (8) to the mounting bracket.
  4. Install the HPR mounting nut (1) and washer.

    Tighten:  Tighten the nut to 54 N.m (40 lb ft).

    5. Fig 3: Identifying High Pressure Regulator (HPR) Inlet Fitting Components
    GM327075Courtesy of GENERAL MOTORS CORP.
  5. Install the filter spring (4), filter (3) and seal (2) into the HPR inlet port.
    6. CAUTION: Refer to Compressed Natural Gas (CNG) O-Ring Caution in Cautions and Notices.
  6. Install the HPR fuel inlet line fitting (6) with a new O-ring. Lubricate the O-ring with petroleum jelly.

    Tighten:  Tighten the fuel line fitting to 48 N.m (35 lb ft).

    7. Fig 4: Identifying High Pressure Regulator (HPR) Components
    GM757008Courtesy of GENERAL MOTORS CORP.
  7. Pull the HPR coolant hoses through the tank mounting frame.
  8. Connect the HPR coolant hoses (3, 5) to the HPR.
  9. Install the HPR fuel outlet line (4) with a new O-ring. Lubricate the O-ring with petroleum jelly.

    Tighten:  Tighten the fuel line fitting to 37 N.m (27 lb ft).

    10. Fig 5: Identifying Fuel Filter/Fuel Line Assembly Components
    GM1203089Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel filter/fuel line assembly into the vehicle.
  11. Install the fuel filter bracket mounting bolts (2, 4).

    Tighten:  Tighten the bolts to 12 N.m (9 lb ft).

    12. Fig 6: Identifying Fuel Line Hold-Down Components
    GM1203079Courtesy of GENERAL MOTORS CORP.
  12. Install the HPR fuel inlet line (3) with a new O-ring. Lubricate the O-ring with petroleum jelly.

    Tighten:  Tighten the fuel line fitting to 37 N.m (27 lb ft).

  13. Install the fuel filter inlet line (2) with a new O-ring. Lubricate the O-ring with petroleum jelly.

    Tighten:  Tighten the fuel line fitting to 37 N.m (27 lb ft).

  14. Install the fuel line mounting clips (1, 4).

    Tighten:  Tighten the check valve fuel line mounting clip bolt (4) to 12 N.m (9 lb ft).

  15. Install the CNG fuel tank. Refer to Fuel Tank Replacement (Pickup with Type 2 Tank)  or Fuel Tank Replacement (Cab/Chassis with Type 2 Tank) .
  16. Fill the cooling system. Refer to Draining and Filling Cooling System (with HP2) Draining and Filling Cooling System (without HP2) in Engine Cooling in the C/K Pickup Service Manual.
  17. Fill the CNG fuel system.
  18. Start the engine and use the J 45878  in order to inspect for CNG fuel system leaks at each serviced fitting. See Special Tools and Equipment .
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