Installation Procedure

Fig 1: View Of Fuel Sender

Courtesy of GENERAL MOTORS CORP.

Install the fuel sender into the fuel tank. Refer to Fuel Sender Assembly Replacement (Utility/Crew Cab) .

Fig 2: Locating Fuel Tank Insulators

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank insulators.

Fig 3: View Of Fuel Sender Assembly

Courtesy of GENERAL MOTORS CORP.

With the aid of an assistant, position and support the fuel tank.
Raise the fuel tank.
Connect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.
Connect the fuel pressure sensor and the fuel sender electrical connectors.

Fig 4: Locating Fuel Tank Straps

Courtesy 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.

Install the fuel tank straps.
Tighten: Tighten the fuel tank strap nuts to 91 N.m (67 lb ft).

Fig 5: Locating Fuel Fill Hose Clamp & Vent Hose Clamp

Courtesy of GENERAL MOTORS CORP.

Connect the fuel fill hose (2) and the vent hose (1) to the fuel tank.
Tighten:
- Tighten the fuel fill hose clamp to 2.5 N.m (22 lb in).
- Tighten the vent hose clamp to 1.7 N.m (15 lb in).
Install the left splash shield.

Fig 6: View Of Fuel Tank Shield

Courtesy of GENERAL MOTORS CORP.

Install the fuel tank shield.
Tighten: Tighten the fuel tank shield bolts to 11 N.m (97 lb in).
Lower the vehicle.
Refill the fuel tank.
Install the fuel tank filler cap.
Connect the negative battery cable.
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.