FUEL SENDER ASSEMBLY REPLACEM... FUEL TANK REPLACEMENT (CAB/CHASSIS FRONT) (ENGINE CONTROLS 4.8L, 5.3L, AND 6.0L) Document ID# 824435 Fuel Tank Replacement (Cab/Chassis Front) Removal Procedure http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 1/10
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief. 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 3. Drain the fuel tank. Refer to Fuel Tank Draining (Pickup). 4. Remove the fuel tank shield (1). http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 2/10
5. Disconnect the fuel fill and vent pipe (2) from the fuel tank. http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 3/10
6. With the aid of an assistant, support the fuel tank. 7. Remove the fuel tank strap attaching bolts. 8. Remove the fuel tank straps (1). 9. Carefully lower the fuel tank slightly. 10. Disconnect the fuel and evaporative emission (EVAP) pipes. Refer to Metal Collar Quick Connect Fitting Service. http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 4/10
11. Disconnect the fuel sender and the fuel pressure sensor harness connectors. 12. Remove the fuel tank. 13. Place the fuel tank in a suitable work area. 14. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement. 15. Cap the fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination. Installation Procedure http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 5/10
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). http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 6/10
7. Install the fuel tank straps (1). Notice: Refer to Fastener Notice in Cautions and Notices. 8. Install the fuel tank strap attaching bolts. Tighten: Tighten the bolts to 40 [n m] (30 lb ft). http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 7/10
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). http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 8/10
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 (Single Battery)Battery Negative Cable Disconnection and Connection (Auxiliary Battery) in Engine Electrical. http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetcat_9 9/10
15. Use the following procedure in order to inspect for leaks: 6.1. Turn ON the ignition, with the engine OFF, for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition, with the engine OFF. 6.4. Inspect for fuel leaks. 16. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)Upper Intake Manifold Sight Shield Replacement (6.0L Engine w/ RPOs Y91 and Z88) in Engine Mechanical. "Portions of materials contained herein have been reprinted with permission of General Motors Corporation, Service and Parts Operations" License Agreement #0410810. Copyright 2007 2012 Service Repair Solutions, Inc. http://dh.identifix.com/searchfixes/index?roid=158586813&vid=2018330&vsm=4&hasbookmark=0&locationid=2#kw=fuel+pump&soption=1&vetid=8&stmode=1&paging=&smode=2&position=assetca... 10/10