2005 Chevrolet ClassicFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: Identifying Fuel Tank
    GM49897Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.
  3. Install the fuel tank retaining straps.

    Tighten:  Tighten the strap bolts to 35 N.m (26 lb ft).

  4. Connect the wiring harness into the multi-way rear body connector.
  5. Connect the EVAP vapor pipe to the EVAP canister.
  6. Connect the fuel filler hose to the fuel tank.

    Tighten:  Tighten the fuel filler hose clamp to 3 N.m (27 lb in).

  7. Install the rubber exhaust hangers.
  8. Install the exhaust heat shield.

    Tighten: 

    • Tighten the exhaust shield bolt to 2 N.m (18 lb in).
    • Tighten the exhaust shield nuts to 1 N.m (9 lb in).

  9. Connect the fuel return pipe and fuel filter quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Lower the vehicle.
  11. Refill the fuel tank.
  12. Install the fuel filler cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.