Installation Procedure

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Fuel Feed & Return Lines At Sending Unit (Pickup)

Courtesy of GENERAL MOTORS CORP.

If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
Install and connect the fuel feed (1) and return (2) lines to the sending unit and retaining clips. Refer to Metal Collar Quick Connect Fitting Service .

Fig 2: View Of Fuel Tank Straps (Pickup)

Courtesy of GENERAL MOTORS CORP.

With the aid of an assistant, place the fuel tank on the jack.
Raise the fuel tank until the sending unit electrical connection can be made.
Connect the sending unit electrical connector.
Install the fuel tank.
Install the fuel tank straps.
CAUTION: Refer to Fastener Caution .
Install the fuel tank strap bolts.
Tighten: Tighten the bolts to 40 N.m (30 lb ft).
Remove the jack from under the fuel tank.

Fig 3: View Of Fuel Feed & Return Lines At Fuel Tank (Pickup)

Courtesy of GENERAL MOTORS CORP.

Remove the caps from the fuel lines.
Connect the fuel feed and return lines to the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .

Fig 4: View Of Fuel Tank Shield & Bolts

Courtesy of GENERAL MOTORS CORP.

If necessary, install the fuel tank shield.
If necessary, install the fuel tank shield bolts.
Tighten: Tighten the bolts to 18 N.m (13 lb ft).
Install the fuel system cooler. Refer to Fuel Cooler Replacement (Pickup) or Fuel Cooler Replacement (Cab/Chassis) .

Fig 5: Identifying Fuel Fill Pipe Assembly

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank fill pipe and vent hose to the fuel tank.
Tighten the fuel tank fill pipe clamp (2) at the fuel tank.
Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
Tighten the fuel tank vent hose clamp (1) at the fuel tank.
Tighten: Tighten the clamp to 2.5 N.m (22 lb in).

Fig 6: Identifying Fuel Tank Fill Pipe Ground Wire Bolt, Ground Wire & Chassis Harness Ground Wire

Courtesy of GENERAL MOTORS CORP.

Position the fuel tank ground strap (3).
Install the fuel tank ground strap bolt (1).
Tighten: Tighten the bolt to 9 N.m (80 lb in).

Fig 7: Identifying Rear Axle Vent Hose On Fuel Fill Pipe

Courtesy of GENERAL MOTORS CORP.

Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
Lower the vehicle.

Fig 8: Identifying Fuel Filler Components

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank filler housing.
Install the fuel tank filler housing to fuel tank fill pipe screws.
Tighten: Tighten the screws to 2.3 N.m (20 lb in).

Fig 9: View Of Fuel Tank Filler Housing To Body Screws & Retainer

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank filler housing to body screws (1), and retainer (2).
Tighten: Tighten the screws to 2.3 N.m (20 lb in).
Fill the fuel tank.
Install the fuel fill cap.
Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) or Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (With Dual Batteries) .
Prime the fuel system. Refer to Fuel System Priming .
Start the engine. If the engine stalls, repeat the above step.
Once the engine starts, inspect for fuel leaks.