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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 947 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Pickup) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine) .
  2. If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
  3. If necessary, install and connect the EVAP purge line (2) to the retaining clips.
  4. If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.
    5. Fig 1: Fuel Feed Line, EVAP Purge Line & FLVV Line
    GM1306291Courtesy of GENERAL MOTORS CORP.
  5. With the aid of an assistant, place the fuel tank onto the adjustable jack.
  6. Raise the fuel tank until the electrical connections can be made.
  7. Connect the fuel sending unit and pressure sensor electrical connectors.
    8. Fig 2: Fuel Pressure Sensor Electrical Connector
    GM1238148Courtesy of GENERAL MOTORS CORP.
  8. Completely raise the fuel tank.

    When raising the tank, ensure that the fill neck on the tank goes over the harness.

  9. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Install the fuel tank strap bolts.

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

    11. Fig 3: Fuel Tank, Strap & Bolts (Pickup)
    GM1228093Courtesy of GENERAL MOTORS CORP.
  11. Remove the adjustable jack from under the fuel tank.
  12. Remove the caps from the fuel and EVAP lines.
    13. Fig 4: Fuel And EVAP Lines At The Fuel Tank
    GM1238591Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel feed and EVAP lines. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. If necessary, install the fuel tank shield.
  15. If necessary, install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

    16. Fig 5: Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  16. Install the EVAP canister vent solenoid. Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup - 5.3L (L59) Engine)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)  or Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis) .
  17. Install the fuel tank fill pipe. Refer to Filler Tube Replacement (Pickup)  or Filler Tube Replacement (Pickup - 5.3L (L59) Engine)  or Filler Tube Replacement (1500 Crew Cab)  or Filler Tube Replacement (Cab/Chassis - Front)  or Filler Tube Replacement (Cab/Chassis - Rear) .
  18. Refill the fuel tank.
  19. Install the fuel cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  21. Perform 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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