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Fuel Tank: Installation

WARNING: This page is about a different car, the 2003 GMC Sierra and 2003 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Natural gas is stored under high pressure. If a leak occurs, the high pressure could cause a personal injury. In order to prevent Compressed Natural Gas (CNG) fuel leaks, always replace the CNG fuel system "O" rings during service.
  1. Lower the fuel tank into the tank mounting frame with the Tank Removal Tool. Place the straps around the tank. Ensure that the High Pressure Lock-Off (HPL) solenoid is properly oriented to the fuel line fittings. Install the tank strap mounting pins and clips.
  2. Install the tank strap mounting nuts. Tighten the tank strap mounting bolts to specification. See TORQUE SPECIFICATIONS  . See Figure . Connect the fuel lines to the HPL fittings with NEW "O" ring face seals. Lubricate the "O" ring face seals with petroleum jelly. Tighten the lines to specification.
  3. Connect the HPL solenoid connectors. Connect the FTP sensor connector. Connect the negative battery cable(s). Tighten cable bolt(s) to specification. Fill the CNG fuel system. Start the engine and use the Combustible Gas Detector in order to inspect for CNG fuel system leaks at each serviced fitting. Install the truck body as required on ZW9 equipped vehicles.


WARNING: Natural gas is stored under high pressure. If a leak occurs, the high pressure could cause a personal injury. In order to prevent Compressed Natural Gas (CNG) fuel leaks, always replace the CNG fuel system "O" rings during service.
  1. Lower the fuel tank into the tank mounting frame ensuring that the High Pressure Lock-Off (HPL) solenoid is properly oriented to the fuel line. Place the straps around the tank. See Fig 3 . Install the tank strap upper mounting pins and clips. Install the tank strap mounting nuts. Tighten the tank strap mounting bolts to specification. See TORQUE SPECIFICATIONS  .
  2. Install the tank upper cover mounting bracket and bolts and tighten to specification. See Fig 2 . Install the tank lower cover mounting bracket and bolts and tighten to specification. Install the fuel filter and line assembly. Tighten the fuel filter mounting bolts to specification. Fasten the fuel line at the lower tank cover mounting bracket and the tank strap.
  3. Connect the fuel line to the HPR fitting using a NEW "O" ring face seal. Lubricate the "O" ring face seal with petroleum jelly. Tighten the fitting to specification. Connect the fitting to the HPL using a NEW "O" ring. Lubricate the "O" ring with petroleum jelly. Tighten the fitting to specification.
  4. Connect the tee to the HPL fitting using a NEW "O" ring face seal. Lubricate the "O" ring face seal with petroleum jelly. Tighten the fitting to specification. Connect the fuel line to the HPL using a NEW "O" ring face seal. Lubricate the "O" ring face seal with petroleum jelly. Tighten the fitting to specification.
  5. Connect the HPL solenoid connectors. Connect the FTP sensor connector. Connect the negative battery cable(s). Tighten cable bolt(s) to specification. Fill the CNG fuel system. Start the engine and use the Combustible Gas Detector in order to inspect for CNG fuel system leaks at each serviced fitting. Install the fuel tank cover.
Fig 1: Removing/Installing HPL Solenoid
G00079508Courtesy of GENERAL MOTORS CORP.
Fig 2: Removing/Installing CNG Tank (Pickup)
G00232198Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing/Installing CNG Tank Straps (Pickup)
G00232204Courtesy of GENERAL MOTORS CORP.
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