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Home › Chevrolet › 2001 › C3500 HD 6.5 F, Automatic › Repair and Diagnosis › Engine Performance › System › Engine Controls - 6.5L (L65) (Introduction) › Repair Instructions › Fuel Tank Replacement (Extended Cab Side Tank) › Installation Procedure

Installation Procedure

    Fig 1: Fuel Sender Seal Ring
    GM263632Courtesy of GENERAL MOTORS CORP.
  1. Install the new seal ring.
  2. Use the J 36608  in order to reinstall the sender. See Special Tools .
  3. Place the tank in the shield.
    4. Fig 2: Fuel Hoses & Lines
    GM19204Courtesy of GENERAL MOTORS CORP.
  4. Raise the tank and shield slightly and reconnect the fuel hoses (2), the lines (1), and the electrical connections at the sender.
    5. Fig 3: Fuel Tank & Shield
    GM18415Courtesy of GENERAL MOTORS CORP.
  5. Raise the tank and shield fully.
    6. Fig 4: Fuel Tank Filler Neck, Clamp & Fuel Tank
    GM18442Courtesy of GENERAL MOTORS CORP.
  6. Reinstall the fuel tank filler neck to the tank.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the clamp.

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

    8. Fig 5: Fuel Tank & Straps
    GM18413Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel tank brackets with insulator strips in place.
    9. NOTE: Refer to Fuel Tank Strap Fastener Notice in Cautions and Notices.
  9. Tighten the strap bolts.

    Tighten:  Tighten the strap bolts to 45 N.m (33 lb ft).

  10. Replenish the fuel in the tank.
  11. Reinstall the fuel tank filler cap.
  12. Reconnect the negative battery cable. If a memory retention device was not used, reset (to the extent possible) all devices that lost their memory after the battery was disconnected.
  13. Check for leaks.
    1. Turn ON the ignition switch for 2 seconds.
    2. Turn OFF the ignition switch for 10 seconds.
    3. Again, turn the ignition switch to the ON position.
    4. Check for fuel leaks.
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