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HOMESERVICE MANUALSCHEVROLET2006SUBURBAN C1500, 5.3 ZREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 382 (ENGINE CONTROLS - 4.3L (INTRODUCTION))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Suburban C1500, 5.3 Z

Installation Procedure

2006 Chevrolet Suburban C1500, 5.3 ZSECTION Installation Procedure
WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
  3. Install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.
    4. Fig 1: View Of EVAP Pipe, Fuel Feed & Return
    GM815641Courtesy of GENERAL MOTORS CORP.
  4. With the aid of an assistant, place the fuel tank on the jack.
  5. Raise the fuel tank until the electrical connections can be made.
  6. Connect the fuel sending unit and pressure sensor electrical connectors (1).
    7. Fig 2: View Of Pressure Sensor Electrical Connectors
    GM878152Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the fuel tank strap bolts.

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

    9. Fig 3: View Of Fuel Tank & Straps
    GM300138Courtesy of GENERAL MOTORS CORP.
  9. Remove the adjustable jack from under the fuel tank.
  10. Remove the caps from the fuel and EVAP pipes.
  11. Connect the fuel feed/return pipes to the fuel tank pipes. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  12. Install the fuel feed/return pipes to the clip on the fuel tank.
    13. Fig 4: View Of Fuel Feed/Return Pipes At Fuel Tank
    GM878130Courtesy of GENERAL MOTORS CORP.
  13. Install the EVAP canister. Refer to Evaporative Emission (EVAP) Canister Replacement .
  14. If necessary, install the fuel tank shield.
  15. Install the fuel tank shield bolts.

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

    16. Fig 5: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  16. Install the fuel tank fill pipe to the vehicle and tank.
  17. Tighten the fuel tank fill pipe clamp at the tank.

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

    18. Fig 6: View Of Fuel Tank Fill Pipe
    GM816694Courtesy of GENERAL MOTORS CORP.
  18. Install the chassis harness ground strap (2) and fuel tank ground strap (4).
  19. Install the fuel tank ground strap bolt (3).

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

    20. Fig 7: View Of EVAP Canister Vent Valve Electrical Connector, Chassis Harness Ground Strap, Fuel Tank Ground Strap Bolt & Fuel Tank Ground Strap
    GM815635Courtesy of GENERAL MOTORS CORP.
  20. Lower the vehicle.
  21. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
    22. Fig 8: View Of Rear Axle Vent Hose At Clip On Fuel Fill Pipe Bracket
    GM816707Courtesy of GENERAL MOTORS CORP.
  22. Install the fuel tank filler housing.
  23. Install the fuel tank filler housing to fuel tank fill pipe screws.

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

    24. Fig 9: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  24. 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).

    25. Fig 10: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  25. Fill the fuel tank.
  26. Inspect the fuel system for leaks using the following procedure:
    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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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.