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Fuel Tank: Installation

  1. Position and support fuel tank, raising front of fuel tank first. Reconnect fuel tank sending unit and fuel pressure sensor harness connectors.
  2. On dual tank models, connect EVAP pipe and fuel feed and return lines at fuel sending unit. See FUEL LINE DISCONNECT FITTINGS . On Suburban, install fuel sending unit cover.
  3. On all models, raise fuel tank and install fuel tank straps. Install fuel tank strap retaining bolts and tighten to specification. See TORQUE SPECIFICATIONS .
  4. To complete installation, reverse removal procedure. Lower vehicle. Add fuel to fuel tank. Turn ignition switch to ON position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to ON position. Check for fuel leaks. Repair as necessary.


  1. If necessary, install the sending unit. Install the tank onto the jack. Raise the fuel tank until the electrical connection can me made. Connect the fuel tank electrical connectors. Remove the caps from the EVAP and fuel pipes. Connect the fuel pipe at the fuel sending unit. See FUEL LINE DISCONNECT FITTINGS . Connect the EVAP tubes.
  2. Install the hose to the retaining clip. Close the retaining clip. Completely raise the fuel tank. Install the fuel tank straps. Install the fuel tank strap bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Remove the jack from the fuel tank.
  3. Install the vent hose to the rear tank. Tighten the vent hose clamp at the rear tank. Install the fill pipe hose to the rear tank. Tighten the fuel tank fill pipe hose clamp at the rear tank. Install the fill hose to the front tank. Tighten the fill hose clamp at the front tank. Install the spare tire hoist crossmember and bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
  4. Install the rear exhaust insulator. Lower the vehicle. Install the spare tire. Install the spare tire stowage lock cylinder. Refill the fuel tank. Install the fuel fill cap. Connect the negative battery cable. Turn ignition switch to ON position for 2 seconds. Turn ignition switch to OFF position for 10 seconds. Turn ignition switch to ON position. Check for fuel leaks. Repair as necessary.
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