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Home >> Chevrolet >> 2004 >> S10 Pickup >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 4.3L (Introduction) >> Repair Instructions >> Fuel Tank Replacement (Pickup) >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Fuel Sender
    GM331709Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel sender into the fuel tank. Refer to Fuel Sender Assembly Replacement (Utility/Crew Cab)  or Fuel Sender Assembly Replacement (Pick-Up) .
    2. Fig 2: View Of Fuel Tank
    GM616741Courtesy of GENERAL MOTORS CORP.
  2. Install the fuel tank insulators.
  3. With the aid of an assistant, position and support the fuel tank.
  4. Raise the fuel tank.
  5. Connect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.
    6. Fig 3: View Of Fuel Sender Assembly
    GM331713Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel pressure sensor and the fuel sender electrical connectors.
  7. Connect the EVAP pipe to the rollover valve.
    8. Fig 4: Locating Fuel Tank Strap Components
    GM616754Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
  8. Install the rear fuel tank strap (4) and the protector (2) to the crossmember with the bolt (3) and the retainer (1).

    Tighten:  Tighten the fuel tank strap bolt to 18 N.m (13 lb ft).

    9. Fig 5: Locating Fuel Tank Rear Strap
    GM616751Courtesy of GENERAL MOTORS CORP.
  9. Install the rear fuel tank strap to frame bolt (3).

    Tighten:  Tighten the fuel tank strap bolt to 18 N.m (13 lb ft).

    10. Fig 6: Installing Rear Fuel Tank Shield
    GM617034Courtesy of GENERAL MOTORS CORP.
  10. Install the rear fuel tank shield (without underbody shield package).
    11. Fig 7: View Of Shield Components
    GM617037Courtesy of GENERAL MOTORS CORP.
  11. Push the shield (2) onto the horizontal flange of the fuel tank (1).
  12. The shield (2) is designed with interference to the bottom of the fuel tank (3).
    13. Fig 8: Locating Fuel Tank Front Shield Components
    GM617032Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank front shield (4), washer (2), and nut (3) (without underbody shield package).

    Tighten:  Tighten the fuel tank shield nut to 25 N.m (18 lb ft).

    14. Fig 9: Locating Fuel Tank Shield Components
    GM617041Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel tank shield to the fuel tank strap bolt (5) with the washer (3) and the nut (4) (4 wheel drive with underbody shield package).
  15. Install the fuel tank shield to frame bolts (2).

    Tighten: 

    1. Tighten the fuel tank shield bolts (2) to 11 N.m (97 lb in).
    2. Tighten the fuel tank shield nut (4) to 25 N.m (18 lb ft).

  16. Install the fuel tank shield to crossmember bolts (1) and nuts (6).

    Tighten:  Tighten the fuel tank shield bolts and nuts to 23 N.m (17 lb ft).

  17. Install the fuel filler pipe. Refer to Filler Tube Replacement (Pickup) , Filler Tube Replacement (2-Door Utility)  or Filler Tube Replacement (4-Door Utility Lower) .
  18. Lower the vehicle.
  19. Refill the fuel tank.
  20. Install the fuel tank filler cap.
  21. Connect the negative battery cable.
  22. Inspect for leaks.
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
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