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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 878 (Engine Controls And Fuel - 4.8L, 5.3L, 6.0L And 6.2L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (15 Ext/Crew Cab w/26 gal Tank) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 GMC Sierra, 2007 GMC Cab & Chassis Sierra, 2007 Chevrolet Silverado, and 2007 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Tank Clips
    GM1854690Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (15 Reg Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crew Cab w/34 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 and 2).
    4. Fig 2: EVAP Pipe Quick Connect Fitting
    GM1854689Courtesy of GENERAL MOTORS CORP.
  4. Position and connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Install the EVAP pipe to the fuel tank clips (1).
    6. Fig 3: Fuel Tank Clips
    GM1854688Courtesy of GENERAL MOTORS CORP.
  6. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Install the fuel feed pipe to the fuel tank clips (1).
    8. Fig 4: Fuel Tank Shield And Push On Retainers
    GM1854687Courtesy of GENERAL MOTORS CORP.
  8. Position and install the fuel tank shield.
  9. Install the fuel tank shield push on retainers.
    10. Fig 5: Chassis Wiring Harness Electrical Connector At Fuel Tank Pressure Sensor And Fuel Tank Module
    GM1854685Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, place the fuel tank in a the adjustable jack.
  11. Raise the fuel tank until the electrical connections can be made.
  12. Connect the chassis wiring harness electrical connector to the fuel tank module.
  13. Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
  14. Completely raise the fuel tank into position.
    15. Fig 6: View Of Fuel Tank And Straps
    GM1854455Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  15. Install the fuel tank straps.
  16. Install the fuel tank strap bolts.

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

  17. Remove the adjustable jack from under the fuel tank.
    18. Fig 7: Quick Connect Fittings
    GM1854683Courtesy of GENERAL MOTORS CORP.
  18. Remove the caps from the fuel and EVAP lines.
  19. Connect the fuel tank EVAP line quick connect fitting (3) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  20. Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    21. Fig 8: Fuel Tank Shield
    GM1853724Courtesy of GENERAL MOTORS CORP.
  21. Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
    22. Fig 9: Fuel Tank Shield & Bolts (1500 Crew Cab)
    GM1501882Courtesy of GENERAL MOTORS CORP.
  22. Install the fuel tank shield bolts, if equipped.

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

  23. Install the fuel tank fill pipe. Refer to Fuel Tank Filler Pipe Replacement (15 Reg Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Filler Pipe Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
  24. Refill the fuel tank.
  25. Install the fuel cap.
  26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (w/Single Battery) or Battery Negative Cable Disconnection and Connection (w/Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (w/Dual Batteries) .
  27. 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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