LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> GMC >> 2001 >> C3500 HD 8.1 G, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 8.1L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement (Front Tank) >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

    Fig 1: Fuel Feed And Return Pipes
    GM570582Courtesy of GENERAL MOTORS COMPANY
  1. Connect the EVAP pipe to the fuel tank roll over valves (2, 4) and the retaining clips (1).
  2. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
    3. Fig 2: Fuel Feed, Return, And EVAP Pipes At Fuel Sender
    GM569633Courtesy of GENERAL MOTORS COMPANY
  3. With the aid of an assistant, support and partially raise the fuel tank front end first.
  4. Connect the fuel sender and the fuel pressure sensor electrical connectors.
  5. Connect the fuel feed, return, and EVAP pipes (1, 2, 3) at the fuel sender.
  6. Install the fuel sender cover, on the suburban only.
    7. Fig 3: Fuel Tank Strap
    GM570588Courtesy of GENERAL MOTORS COMPANY
  7. Fully raise the fuel tank.
  8. Install the fuel tank straps.

    Refer to FASTENER NOTICE in Cautions and Notices.

  9. Install the fuel tank strap bolts.

    Tighten 

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

    10. Fig 4: Fuel Tank Fill And Vent Hoses
    GM569669Courtesy of GENERAL MOTORS COMPANY
  10. Connect the vent hose (6) to the fuel tank.

    Tighten 

    Tighten the vent hose clamp (7) to 2.5 N.m (22 lb in)

    11. Fig 5: Fuel Fill Hose
    GM570570Courtesy of GENERAL MOTORS COMPANY
  11. Connect the fuel fill hose (2) to the fuel tank.

    Tighten 

    Tighten the fuel fill hose clamp (1) to 2.5 N.m (22 lb in)

    12. Fig 6: Vent Valve Pipe
    GM625803Courtesy of GENERAL MOTORS COMPANY
  12. Connect the EVAP vent pipe to the fuel tank clip (5).
    13. Fig 7: Evaporative Emission Canister
    GM569589Courtesy of GENERAL MOTORS COMPANY
  13. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement (Utility) , Evaporative Emission Canister Replacement (Cab/Chassis) , Evaporative Emission Canister Replacement (Pickup) .
  14. Lower the vehicle.
  15. Refill the fuel tank.
  16. Install the fuel filler cap.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Auxiliary Battery) , Battery Negative Cable Disconnection and Connection (Single Battery) in Engine Electrical.
  18. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  19. Install the engine sight shield.
scientia non olet · About LEMON Manuals