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Home >> Cadillac >> 2003 >> Escalade EXT >> Repair and Diagnosis >> External Pages >> Different car >> Section 331 (Engine Controls - 8.1L (Introduction)) >> Repair Instructions >> Fuel Tank Replacement (Pickup) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. With the aid of an assistant, place the fuel tank onto the adjustable jack.
  3. Raise the fuel tank until the electrical connections can be made.
  4. Connect the fuel sending unit and pressure sensor electrical connectors.
    Fig 1: Fuel Sending Unit And Fuel Pressure Sensor Electrical Connectors - Pickup
    GM1238148Courtesy of GENERAL MOTORS CORP.
  5. Completely raise the fuel tank.
    6. Fig 2: Fuel Tank Assembly
    GM1228093Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts.

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

  8. Remove the adjustable jack from under the fuel tank.
  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the fuel feed and EVAP quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    11. Fig 3: Fuel Tank Shield
    GM626413Courtesy of GENERAL MOTORS CORP.
  11. If necessary, install the fuel tank shield.
  12. Install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

    13. Fig 4: EVAP Canister Vent Solenoid
    GM1228110Courtesy of GENERAL MOTORS CORP.
  13. Install the EVAP canister vent solenoid to the fuel tank.
  14. Connect the EVAP canister vent solenoid electrical connector.
  15. Install the fuel tank fill pipe. Refer to Filler Tube Replacement (Pickup)  or Filler Tube Replacement (Cab/Chassis - Front)  or Filler Tube Replacement (Cab/Chassis - Rear) .
  16. Refill the fuel tank.
  17. Install the fuel cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  19. Perform the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
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