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Home › Chevrolet › 2001 › C3500 HD 8.1 G, Automatic › Repair and Diagnosis › Engine Performance › System › Engine Controls - 8.1L - Repair Instructions › Repair Instructions › Fuel Tank Replacement (Cab/Chassis Front Tank) › Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank, Strap & Bolts (Cab/Chassis - Front)
    GM667731Courtesy of GENERAL MOTORS COMPANY
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, support and partially raise the fuel tank.
  4. Connect the fuel sender and the fuel pressure sensor harness connectors.
  5. Connect the fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
  6. Fully raise the fuel tank (2).
  7. Install the fuel tank straps (1).
  8. Refer to FASTENER NOTICE in Cautions and Notices.

    Install the fuel tank strap bolts.

    Tighten 

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

    9. Fig 2: Fuel Fill And Vent Pipe
    GM667876Courtesy of GENERAL MOTORS COMPANY
  9. Connect the fuel fill and vent pipe (2) to the fuel tank.

    Tighten 

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

    10. Fig 3: Fuel Tank Shield
    GM667724Courtesy of GENERAL MOTORS COMPANY
  10. Install the fuel tank shield (1).
  11. Lower the vehicle.
  12. Refill the fuel tank (2).
  13. Install the fuel filler cap.
  14. 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.
  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.
  16. Install the engine sight shield.
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