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Home >> GMC >> 2005 >> Jimmy Part Time, Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - (Introduction) >> Repair Instructions >> Fuel Tank Replacement (4-Door Utility) >> Installation Procedure
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Installation Procedure

  1. Install the fuel sender into the fuel tank. Refer to Fuel Sender Assembly Replacement (Utility/Crew Cab) .
  2. Install the fuel tank insulators.
    3. Fig 1: Locating Fuel Tank Components
    GM747558Courtesy of GENERAL MOTORS CORP.
  3. With the aid of an assistant, position and support the fuel tank.
    4. NOTE: Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel tank straps (1).

    Tighten: 

    • Tighten the fuel tank strap nut (3) to 18 N.m (13 lb ft).
    • Tighten the fuel tank strap bolt (2) to 18 N.m (13 lb ft).

    5. Fig 2: Locating Fuel Feed, Return, & EVAP Purge Pipes At Fuel Sender
    GM747555Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel feed, return, and EVAP purge pipes (2, 3, 4) at the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    6. Fig 3: Locating Fuel Pressure Sensor & The Fuel Sender Harness Connectors
    GM747556Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel pressure sensor and the fuel sender harness connectors (2, 3) to the fuel sender (1).
  7. Connect the vent hose to the rollover valve at the front of the fuel tank.
  8. Connect the vent hoses to the fuel limiter vent valve.
    9. Fig 4: Locating Fuel Fill Hose Components
    GM748093Courtesy of GENERAL MOTORS CORP.
  9. Connect the lower fuel fill hose (13) to the fuel tank and lower fuel fill tube (12).

    Tighten:  Tighten the fuel fill hose clamps (1, 2) to 2.5 N.m (22 lb in).

    10. Fig 5: View Of Fuel Tank Shield
    GM747563Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel tank shield (2).

    Tighten:  Tighten the fuel tank shield bolts (3, 4) to 33 N.m (24 lb ft).

  11. Lower the vehicle.
  12. Remove the fuel fill cap and refill the fuel tank.
  13. Install the fuel tank filler cap.
  14. Connect the negative battery cable.
  15. 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.
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