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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1311 (Engine Controls And Fuel - 4.8L, 5.3L, 6.0L, 6.2L - Introduction (1 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) >> Installation Procedure

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: Identifying Fuel Tank Clips
    GM1854930Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 Gal Tank) , Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 Gal Tank) , Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 Gal Tank) , Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 Gal Tank)  or Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank) .
  2. Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  3. Install the EVAP pipe to the fuel tank clips (1).
    4. Fig 2: Identifying EVAP Pipe & Fuel Tank Clips
    GM1854928Courtesy of GENERAL MOTORS CORP.
  4. Install the EVAP pipe to the fuel tank clips (1).
    5. Fig 3: Identifying Fuel Feed Pipe Quick Connect Fitting & Fuel Tank Clips
    GM1854927Courtesy of GENERAL MOTORS CORP.
  5. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Install the fuel feed pipe to the fuel tank clips (1).
    7. Fig 4: Identifying Fuel Tank Shield & Push On Retainers
    GM1854926Courtesy of GENERAL MOTORS CORP.
  7. Position and install the fuel tank shield.
  8. Install the fuel tank shield push on retainers.
    9. Fig 5: Identifying Chassis Wiring Harness Electrical Connector At Fuel Tank Pressure Sensor & Fuel Tank Module
    GM1854941Courtesy of GENERAL MOTORS CORP.
  9. With the aid of an assistant, place the fuel tank in a the adjustable jack.
  10. Raise the fuel tank until the electrical connections can be made.
  11. Connect the chassis wiring harness electrical connector (2) to the fuel tank module.
  12. Connect the chassis wiring harness electrical connector (1) from the fuel pressure sensor.
  13. Completely raise the fuel tank into position.
    14. Fig 6: View Of Fuel Tank & Straps
    GM1854455Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Fastener Caution .
  14. Install the fuel tank straps.
  15. Install the fuel tank strap bolts.

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

  16. Remove the adjustable jack from under the fuel tank.
    17. Fig 7: Identifying Quick Connect Fittings
    GM1854925Courtesy of GENERAL MOTORS CORP.
  17. Remove the caps from the fuel and EVAP lines.
  18. Connect the fuel tank EVAP line quick connect fitting (2) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  19. Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    20. Fig 8: Identifying EVAP Canister Vent Solenoid Retainer
    GM1855688Courtesy of GENERAL MOTORS CORP.
  20. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
  21. Ensure that the retainer (1) is engaged, securing the EVAP canister vent solenoid.
    22. Fig 9: Identifying Fittings At Fuel Tank
    GM1854924Courtesy of GENERAL MOTORS CORP.
  22. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  23. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
  25. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
  26. Install the chassis wiring harness clip to the fuel tank shield.
    27. Fig 10: View Of Fuel Tank & Shield
    GM1854937Courtesy of GENERAL MOTORS CORP.
  27. Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
    28. Fig 11: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  28. Install the fuel tank shield bolts, if equipped.

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

  29. Install the fuel tank fill pipe. Refer to Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 Gal Tank) , Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 Gal Tank) , Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew cab w/34 Gal Tank) , Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 Gal Tank)  or Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 Gal Tank) .
  30. Refill the fuel tank.
  31. Install the fuel cap.
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) , Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (With Dual Batteries) .
  33. 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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