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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 (Pickup) >> Installation Procedure
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Installation Procedure

  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the fuel fill and vent hose and pipe assembly to the fuel tank.

    Tighten 

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

    3. Fig 1: View Of EVAP Hoses/Pipes (Canister/Fuel Tank)
    GM396067Courtesy of GENERAL MOTORS COMPANY
  3. Connect the EVAP pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the retaining clips (6).
  4. Connect the fuel feed pipe (4) and the fuel return pipe (5) to the fuel sender and the retaining clips.
    5. Fig 2: View Of Fuel Tank & Straps
    GM300138Courtesy of GENERAL MOTORS COMPANY
  5. With the aid of an assistant, position and support the fuel tank.
  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts.

    Tighten 

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

    8. Fig 3: Fuel Tank Shield
    GM626414Courtesy of GENERAL MOTORS COMPANY
  8. Install the fuel tank shield to the fuel tank clips.
    9. Fig 4: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS COMPANY
  9. Install the fuel tank shield to frame bolts.

    Tighten 

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

    10. Fig 5: Fuel Sender And The Fuel Pressure Sensor Electrical Connectors
    GM373155Courtesy of GENERAL MOTORS COMPANY
  10. Connect the fuel sender and the fuel pressure sensor electrical connectors.
    11. Fig 6: Chassis Fuel Pipes
    GM303903Courtesy of GENERAL MOTORS COMPANY
  11. Remove the caps from the fuel and EVAP pipes.
  12. Connect the rear fuel return pipe and the rear fuel feed pipe at the chassis fuel pipes. Refer to Plastic Collar Quick Connect Fitting Service .
    13. Fig 7: Evaporative Emission Canister
    GM303981Courtesy of GENERAL MOTORS COMPANY
  13. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement (Pickup) .
    14. Fig 8: Fuel Tank Ground Strap & Bolt
    GM420291Courtesy of GENERAL MOTORS COMPANY
  14. Connect the fuel fill pipe ground strap.

    Tighten 

    Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in).

  15. Lower the vehicle.
    16. Fig 9: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS COMPANY
  16. Connect the fuel fill pipe to the fuel fill pipe housing.

    Tighten 

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

  17. Refill the fuel tank.
  18. Install the fuel filler cap.
  19. 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.
  20. 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.
  21. Install the engine sight shield.
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