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Fuel Tank: Installation

NOTE: Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.
  1. Position and support the fuel tank with the aid of an assistant. Connect the fuel sender and the fuel tank pressure sensor electrical connectors. Install the fuel tank straps. Install the fuel tank strap bolts. Tighten the fuel tank strap bolts to specification. See TORQUE SPECIFICATIONS .
  2. Position the tank shield, and install the three push pins. Connect the quick-connect fittings at the fuel filter and chassis. Connect the EVAP pipe at the front of the fuel tank. Connect the fuel tank filler hose to the fuel tank. Connect the filler vent pipe at the filler hose/pipe connection.
  3. Connect the two parts of the EVAP fresh air hose at the splice. Fully seat the filler hose on fuel tank port. Make sure clamp is properly located on tank port between the bead and tank. See Figure.
  4. Tighten the fuel tank filler pipe hose clamp to specification. Install the rubber exhaust pipe hangers. Lower the vehicle. Add fuel and install the fuel filler pipe cap. Connect the negative battery cable. Inspect for fuel leaks using the following procedure. Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.


  1. Install the fuel tank to a suitable jack. Connect the EVAP pipes to the rear of the fuel tank. Connect the EVAP pipe to the fuel limiter vent valve. Connect the fuel filler EVAP pipe at the rear of the fuel tank. Raise the fuel tank to the original position.
  2. Install the fuel tank retaining strap bolts. Tighten the fuel tank retaining strap bolts to specification. See TORQUE SPECIFICATIONS . Remove the jack from the fuel tank. Connect the quick-connect fittings at the fuel tank. Connect the EVAP pipe at the front of the fuel tank. Install the fuel tank filler hose to the fuel tank.
  3. Inspect and make sure that the filler hose is fully seated on fuel tank port. Make sure the clamp is properly located on tank port between the bead and the tank. See Figure. Tighten the hose clamp to specification. Install the exhaust pipe to the exhaust hangers. Inspect the fuel and EVAP pipes making sure they were not kinked or damaged during removal and installation.
  4. Lower the vehicle. Add fuel and install the fuel fill cap. Connect the negative battery cable. Inspect for fuel leaks using the following procedure. Turn ON the ignition, for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition. Inspect for fuel leaks. Install fuel injection sight shield.
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