FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
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Home >> Chevy Truck >> 2001 >> Express 1 Ton Van V8-5.7L VIN R >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Tank >> Service and Repair >> Removal and Replacement >> Fuel Tank Replacement >> Fuel Tank Replacement (Bi-Fuel/Alternative Fuels) >> Front

Front

TOOLS REQUIRED
^ J 41416 Ultrasonic Leak Detector
^ J 45038 CNG Tank Lifting Fixture

REMOVAL PROCEDURE




1. Relieve the CNG fuel system pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Disconnect the negative battery cable.
3. Remove the fuel tank shield.
4. Vent the CNG fuel from the CNG fuel tank if necessary. Refer to Fuel Tank Venting Procedure.
5. Disconnect the electrical connectors at the high pressure lock-off solenoid as necessary.
6. Disconnect the fuel outlet line (4) from the high pressure lock-off (HPL) solenoid (2).




7. Disconnect the fuel inlet line (4) at the high pressure lock-off solenoid fitting (6).

IMPORTANT: The front and rear fuel tanks are not interchangeable. Mark the tanks as front and rear prior to removal from the vehicle.




8. Place the J 45038 using a suitable lifting device such as a transmission lift jack beneath the tank to be removed ensuring placement is between the tank straps.
9. Remove and discard the retaining nut and bolt (5).
10. Remove the tank strap upper mounting pins (3).
11. Remove the tank straps (4) from the vehicle.
12. Lower the fuel tank from the vehicle.

INSTALLATION PROCEDURE




1. Raise the fuel tank into the tank mounting frame ensuring that the high pressure lock-off solenoid is properly oriented to the fuel lines.
2. Place the straps (4) into the tank mounting bracket.
3. Install the tank strap upper mounting pins (3).

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the new tank strap mounting nuts and bolts (5).

Tighten
Tighter the tank strap mounting bolts to 47 N.m (35 lb ft).




5. Connect the fuel inlet line (4) at the front tank (1) high pressure lock-off solenoid fitting (6) using new O-rings. Lubricate the O-rings with petroleum jelly or equivalent.

Tighten
Tighten the fitting to 37 N.m (27 lb ft).




6. Connect the fuel outlet line (4) to the high pressure lock-off (2) using new O-rings. Lubricate the O-rings with petroleum jelly or equivalent.

Tighten
Tighten the fitting to 37 N.m (27 lb ft).

7. Connect the electrical connectors at the high pressure lock-off solenoid as necessary.
8. Connect the negative battery cable.
9. Prime the CNG fuel system by cycling the ignition ON and OFF several times.
10. Stan the engine and use the J 41416 in order to inspect for CNG fuel system leaks at each serviced fitting.

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