GM 15124940
Upper Hose

The first step to replace a single tank fuel tube requires cleaning both fuel connections and nearby areas to avoid contamination followed by removal of the fuel fill cap. The next step should begin with the torx(R) screws that secure both the Fuel Tank filler housing to body and its retainer. The procedure begins with the removal of the spare tire stowage lock cylinder together with the spare tire if required. Disconnect the screws which link the Fuel Tank filler housing to the fill pipe. The vehicle requires proper suspension while it is elevated. Use a tool to open the rear axle vent hose clip at the fill pipe while removing the vent tube from the hose. The air suspension hose should be removed from the fill pipe if it is present. First detach the ground wire harness bolt before removing the ground wire and fill pipe ground strap. To conduct the replacement disconnect the vent hose quick connector at the Fuel Tank then remove the fuel fill pipe bracket screws and unclench the fuel fill pipe bracket bolts. Remove the fuel fill pipe hose from the Fuel Tank as a first step before pulling out both tubes while securing the Fuel Tank opening through capping. To perform installation begin by uncapping the Fuel Tank opening then connect the fuel fill pipe hose to the tank followed by installing the fuel fill pipe bracket bolts before you tighten them to 12 n.m (106 lb in). Attach the vent hose quick connect fitting to the tank while tightening the fuel fill pipe hose clamp to 2.5 n.m (22lb in). Secure the fill pipe ground strap and ground wire then put the ground wire harness bolt into place while tightening it to 9 n.m (80 lb in). Install the air suspension hose at the fill pipe before securely attaching the vent hose to its clip. Position the vehicle at the lowest height before installing screws between the Fuel Tank filler housing and fill pipe while tightening them to 2.3 n.m (20 lb in). Complete the installation by fastening the torx(R) screws and retainer of the Fuel Tank filler housing to the body while tightening them to 2.3 n.m (20 lb in). If needed, reinstall the spare tire along with its stowage lock cylinder before placing the fuel fill cap.

The first step in replacing the Fuel Filler Hose of single tank system requires cleaning both fuel connections and neighboring areas to prevent contaminants from entering followed by fuel fill cap removal. Start by removing the torx(r) screws and retainer which hold the Fuel Tank filler housing to the body while also taking out any spare tire stowage lock cylinder or spare tire that exists. Untighten and pull out screws which join the Fuel Tank filler housing to the Fuel Tank fill pipe. Rise the vehicle while supporting it before you unclip and remove the vent hose at the fill pipe. Begin by disconnection of the air suspension hose at the fill pipe and continuing with removal of the ground wire harness bolt, ground wire, and fill pipe ground strap. First disconnect the quick connect fitting of the vent hose at the Fuel Tank while loosening the fuel fill pipe clamp before you remove the fuel fill pipe bracket bolts. Remove the fuel fill pipe hose from the Fuel Tank before taking out both the fuel fill pipe and vent hose while applying a cap to the open Fuel Tank end to stop contamination. Basically for installation users need to uncapture the Fuel Tank opening to join the fuel fill pipe hose to the Fuel Tank followed by installing the fuel fill pipe bracket bolts and tightening them to 12 n.m (106 lb in). Install the fuel fill pipe hose by tightening the clamp to 2.5 n.m (22 lb in) and attach the vent hose quick connect fitting to the tank. Attach the fill pipe ground strap with its ground wire while tightening the ground wire harness bolt to 9 n.m (80 lb in). You should first reestablish the air suspension hose connection to the fill pipe before installing the vent hose to its clip then securing the clip at the fill pipe. The technician should first lower the vehicle before securely attaching the Fuel Tank filler housing to Fuel Tank fill pipe screws that require tightening to 2.3 n.m (20 lb in). Next, install the torx(r) screws while securing the retainer between the Fuel Tank filler housing and body with a torque of 2.3 n.m (20 lb in). Reinstall the spare tire along with the stowage lock cylinder but replace the Fuel Tank filler housing with body torx(r) screws and retainer before putting on the fuel fill cap.

The first step to replace the filler pipe of the 2500 series Fuel Tank involves removing the rear Fuel Tank. Start by unfastening the chassis wiring harness ground bolt as well as the left rear lamp ground wire and fill pipe ground strap which mounts to the frame. First disconnect the rear axle vent hose clip from the fill pipe neck. Then loosen the Fuel Tank fill hose clamp located at the front tank while removing the fuel fill hose evaporative emission (EVAP) line quick connect fitting from the Fuel Tank line. Start by removing the front tank fuel fill hose together with the integral clamp secured to the crossmember before you disassemble the fuel fill hose/pipe assembly. Gas contamination will be prevented by using caps on both the Fuel Tank's opening and the fuel and evap lines' open ends. The replacement process for any serviceable component of the fill pipe assembly starts with separating it by unbonding the evaporative emission canister hose followed by unclamping the canister hose clamp and Fuel Tank fill pipe clamp and removing the fill pipe housing bolts then dismantling the fill pipe housing and fill pipe restrictor plus the fill pipe clamp and vent hose and fill hose clamp before releasing the canister hose clip and fill pipe. The assembly process requires torquing the Fuel Tank fill hose clamp to 2.5 nm (22 lb in) as well as tightening the fill pipe , canister hose clip , fill hose clamp to 2.5 nm (22 lb in), vent hose , fill pipe clamp to 2.5 nm (22 lb in), fill pipe restrictor , fill pipe housing , fill pipe housing bolts to 2.3 nm (20 lb in), fill pipe clamp to 2.5 nm (22 lb in), and canister hose clamp to 2.5 n start installation by removing protective covers from both ends of the front Fuel Tank and fuel/evap tubes before adding the fuel fill hose/pipe component and securing the front tank hose connection. Fasten the quick connect fitting between the Fuel Tank line and fuel fill hose evap line while tightening the Fuel Tank fill hose clamp to 2.5 nm (22 lb in). Install the integral clamp to the crossmember and attach the rear axle vent hose clip to the fill pipe neck. The fill pipe ground strap needs to be placed at the left rear lamp ground wire before attaching both to the frame and inserting the chassis wiring harness ground bolt with 9 nm (80 lb in) torque. The last step includes reinstalling the rear Fuel Tank.

The first step to replace the 2500 series Fuel Tank filler pipe requires removal of the rear Fuel Tank. First remove the chassis wiring harness ground bolt followed by the left rear lamp ground wire and fill pipe ground strap from their frame attachments. First detach the axle vent hose clip from the fill pipe neck. Next relax the Fuel Tank fill hose clamp around the front tank and separate the evap fuel fill hose quick connect fitting from the Fuel Tank line. Start the procedure by removing the fuel fill hose from the front tank then taking out its crossmember integral clamp before removing the fuel fill hose/pipe assembly. Apply Fuel Tank caps to seal both open fittings as well as the fuel/evap lines to protect against contamination. Disassembly of all parts comprising the evaporative emission canister hose , canister hose clamp , fill pipe clamp , housing bolts , housing , fill pipe restrictor , vent hose and fill hose clamp must be completed when replacing any functional part of the fill pipe assembly. The assembly process requires the Fuel Tank fill hose clamp to reach 2.5 nm (22 lb in) tightness alongside the fill pipe, canister hose clip, fill hose clamp set to 2.5 nm (22 lb in), vent hose, fill pipe clamp at 2.5 nm (22 lb in), fill pipe restrictor, housing, housing bolts fastened to 2.3 nm (20 lb in), fill pipe clamp set to 2.5 nm (22 lb in), and canister hose clamp tightened to 2.5 nm (22 lb in). Users must remove caps from the front Fuel Tank openings and fuel/evap lines to install the fuel fill hose/pipe assembly by connecting it to the front tank. The Fuel Tank fill hose clamp should be tightened to 2.5 nm (22 lb in) before you install the integral clamp to the crossmember and connect the rear axle vent hose clip to the fill pipe neck. Fasten the fill pipe ground strap to the left rear lamp ground wire before installing both to the frame and using the chassis wiring harness ground bolt with a torque of 9 nm (80 lb in). Replace the rear Fuel Tank as the last installation step.

The first step to replace the fuel tank filler pipe demands users to clean fuel connections along with surrounding areas to stop contamination before they extract the fuel fill cap. Start by removing the torx(R) screws and retainer fixing the fuel tank filler housing to the body followed by taking out the spare tire stowage lock cylinder when needed along with the retainer. Raise the vehicle for support while you detach the clip holding the rear axle vent hose to the fill pipe before taking out the air suspension hose by the fill pipe. The chassis wiring harness ground bolt along with the left rear lamp ground wire and the fill pipe ground strap should be removed from the frame. First loosen the clamp around the fuel fill hose and disconnected the fill hose from the fuel tank. You should disconnect the fuel fill pipe vent line quick connect fitting from its connection to the evaporative emission (EVAP) canister vent solenoid valve while also loosening the fuel tank vent valve clamp on the fuel fill pipe vent hose. Music the fuel fill pipe bracket bolts at positions 2 and 4 then use caps to seal both the fuel tank opening and evap vent line to avoid contamination and extract the fuel fill pipe assembly. The replacement of any parts in the fill pipe assembly requires complete disassembly of components starting from fuel tank filler vent hose followed by fuel tank fill pipe housing bolts before moving to fuel tank fill pipe housing and continuing with fuel tank fill hose and then fuel tank fill pipe clip and finally fuel tank fill hose clamp and evaporative emission hose and evaporative emission hose clamp. The proper torque settings during installation are 2.5 nm (22 lb in) for the evaporative emission hose clamp and 2.5 nm (22 lb in) and 2.3 nm (20 lb in) for both fuel tank fill hose clamps and fuel tank fill pipe housing bolts. Begin fuel tank installation by removing both caps from the fuel tank opening and evap vent line and position the fuel fill hose into the fuel tank with correct alignment. The process includes connecting the fuel fill pipe vent hose to the fuel tank vent valve followed by positioning the tab on the fuel fill pipe into the frame notch then securing fuel fill pipe bracket bolts (2, 4) at 12 nm (106 lb in). Fasten the evap canister vent solenoid valve to the fuel fill pipe vent line quick connect fitting and tighten both the fuel fill hose clamp and fuel fill pipe vent hose clamp to 2.5 nm (22 lb in ). You should position the fill pipe ground strap opposite the left rear lamp ground wire before framing both parts for a 9 nm (80 lb in) tightness on the chassis wiring harness ground bolt. When needed connect the air suspension hose to the fill pipe while also attaching the vent hose clip to the retainer and finally secure the fuel tank filler housing with body torx(R) screws to 2.3 nm (20 lb in). Finish the procedure by installing spare tire components along with stowage lock cylinders (when present) before putting back the fuel fill cap.

Loosen the fuel tank fill hose clamp at the front tank and disconnect the fuel fill hose evaporative emission (EVAP) line quick connect fitting from the fuel tank line before removing the fuel fill hose from the front tank.

Loosen the fuel tank fill hose clamp at the front tank.

Unscrew the TORX(R) screws and retainer to detach the fuel tank filler housing from the body.

Cap the open end of the fuel tank and the open ends of the fuel/EVAP lines to prevent contamination.