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Home › GMC › 2001 › C3500 HD 8.1 G, Automatic › Repair and Diagnosis › Engine Performance › System › Engine Controls - 8.1L - Repair Instructions › Repair Instructions › Fuel Tank Replacement (Rear Tank) › Installation Procedure

Installation Procedure

    Fig 1: Fuel Tank Hoses And Roll Over Valves
    GM570577Courtesy of GENERAL MOTORS COMPANY
  1. Install the EVAP pipes to the fuel tank roll over valves (1, 3) and the retaining clips (2), if required.
  2. Install the fuel sender assembly, if required. Refer to Fuel Sender Assembly Replacement .
  3. With the aid of an assistant, install the tank to the jack.
  4. Partially raise the fuel tank.
    5. Fig 2: Fuel Tank Electrical Connectors
    GM853734Courtesy of GENERAL MOTORS COMPANY
  5. Connect the fuel tank electrical connector.
    6. Fig 3: Evaporative Emission (EVAP) Tubes
    GM853728Courtesy of GENERAL MOTORS COMPANY
  6. Remove the caps from the fuel and EVAP pipes.
  7. Connect the fuel pipe at the fuel sender (1).
  8. Connect the EVAP tubes (2) at the EVAP pipes.
    9. Fig 4: Fuel Tank Filler Hose Clamp
    GM853732Courtesy of GENERAL MOTORS COMPANY
  9. Install the filler hose to the rear tank.
  10. Position the hose clamp screw downwards, for easy access.

    Refer to FASTENER NOTICE in Cautions and Notices.

  11. Tighten the fuel tank filler hose clamp at the rear tank.

    Tighten 

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

    12. Fig 5: Fuel Tank And Straps
    GM570586Courtesy of GENERAL MOTORS COMPANY
  12. Completely raise and install the tank.
  13. Install the fuel tank straps.
  14. Install the fuel tank strap bolts.

    Tighten 

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

  15. Remove the jack from the fuel tank.
  16. Lower the vehicle.
    17. Fig 6: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS COMPANY
  17. Install the fuel filler pipe to the vehicle.
  18. Install the fuel tank filler housing to the vehicle.
  19. Install the fuel tank filler housing to fuel tank filler pipe screws.

    Tighten 

    Tighten the screws to 2.3 N.m (20 lb in).

    20. Fig 7: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS COMPANY
  20. Install the fuel tank filler housing to body screws (1) and retainer (2).

    Tighten 

    Tighten the screws to 2.3 N.m (20 lb in).

  21. Raise the vehicle.
    22. Fig 8: Fuel Vent Hose
    GM569704Courtesy of GENERAL MOTORS COMPANY
  22. Install the vent hose (3) to the vent pipe (1).
  23. Tighten the vent hose clamp (2) at the vent pipe (1).

    Tighten 

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

    24. Fig 9: Fuel Tank Filler Pipe Hose Clamp
    GM853727Courtesy of GENERAL MOTORS COMPANY
  24. Connect the filler pipe to the rear tank.
  25. Tighten the fuel tank filler pipe hose clamp at the rear tank.

    Tighten 

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

    26. Fig 10: Fuel Pipe Ground Strap
    GM853726Courtesy of GENERAL MOTORS COMPANY
  26. Align and position the chassis wiring harness ground strap (2) and fuel filler pipe ground strap (1).
  27. Install the fuel pipe ground strap bolt.

    Tighten 

    Tighten the bolt to 9 N.m (80 lb in).

    28. Fig 11: Fuel Tank Filler Hose
    GM853733Courtesy of GENERAL MOTORS COMPANY
  28. Install the filler hose to the front tank.
  29. Tighten the fuel tank filler hose clamp at the front tank.

    Tighten 

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

  30. Install the rear crossmember that holds the spare tire.
  31. Install the rear exhaust hanger bolts and hanger.
  32. Lower the vehicle.
  33. Install and raise the under chassis mounted spare tire.
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