Fuel Tank: Installation
WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
- Remove the caps from the fuel pipes. With the aid of an assistant, place the fuel tank on the jack. Raise the fuel tank enough to connect the fuel feed/return pipes to the sender assembly. See QUICK CONNECT FITTINGS (METAL COLLAR) . Connect the sender assembly electrical connector.
- Raise the fuel tank. Install the fuel tank straps. Install the fuel tank strap bolts to specification. See TORQUE SPECIFICATIONS . Remove the jack from under the fuel tank. Install the fuel tank shield. See Fig 1. Install the fuel tank shield bolts and tighten to specification.
- Install the fuel fill and vent hose to the tank. Tighten the fuel fill and vent hose clamps to specification. Lower the vehicle. Fill the fuel tank. Install the fuel fill cap. Install the negative battery cables. Tighten battery cable bolts to specification. Command the fuel transfer pump on with a scan tool. Test for fuel leaks. Prime fuel system, if necessary. See FUEL SYSTEM PRIMING .
- Remove the caps from the fuel pipes. With the aid of an assistant, place the fuel tank on the jack. Raise the fuel tank enough to connect the fuel feed/return pipes to the sender assembly. See QUICK CONNECT FITTINGS (METAL COLLAR) . Connect the sender assembly electrical connector.
- Raise the fuel tank. Install the fuel tank straps. Install the fuel tank strap bolts to specification. See TORQUE SPECIFICATIONS . Remove the jack from under the fuel tank.
- Install the fuel tank shield. See Fig 1 Install the fuel fill pipe and vent hose to the tank. Tighten the fuel fill and vent hose clamps at the fuel tank to specification. Connect the fuel feed and pressure balance rear pipes. Lower the vehicle. Fill the fuel tank. Install the fuel fill cap.
- Connect the negative battery cables. Tighten battery cable bolts to specification. Prime the fuel system. See FUEL SYSTEM PRIMING . Start the engine and test for fuel leaks.
- If the fuel tank was replaced, install the sending unit. See FUEL SENDER ASSEMBLY . Install and connect the fuel feed and return pipes to the sending unit and retaining clips. See QUICK CONNECT FITTINGS (PLASTIC COLLAR) .
- With the aid of an assistant, place the fuel tank on the jack. Raise the fuel tank until the electrical connector is accessible. Connect the sending unit electrical connector. Install the fuel tank. Install the fuel tank straps. Install the fuel tank strap bolts and tighten to specification. See TORQUE SPECIFICATIONS .
- Remove the jack from under the fuel tank. Remove the caps from the fuel pipes. Connect the fuel feed and return pipes from the fuel tank pipes. See QUICK CONNECT FITTINGS (METAL COLLAR) .
- Install the fuel tank shield. See Fig 1. Install the fuel tank shield bolts and tighten to specification. Install the fuel system cooler. See FUEL SYSTEM COOLER . Install the fuel tank fill pipe to the fuel tank and vehicle. Tighten the fuel tank fill pipe clamp at the fuel tank to specification.
- Install the fuel tank ground strap. Install the fuel tank ground strap bolt. Tighten the bolt to specification. Lower the vehicle. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. Install the fuel tank filler housing. Install the fuel tank filler housing to fuel tank fill pipe screws. Tighten the screws to specification.
- Install the fuel tank filler housing to body screws, and retainer. Tighten the screws to specification. Fill the fuel tank. Install the fuel fill cap. Connect the negative battery cables. Tighten battery cable bolts to specification. Prime the fuel system. See FUEL SYSTEM PRIMING . Start the engine and test for fuel leaks.