GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Avalanche - 4WD 🢒 Engine 🢒 Engine Controls - 8.1L 🢒 Filler Tube Replacement

Removal Procedure

    Object Number: 300314 Size: SH
  1. Remove the fuel fill cap.
  2. If necessary, drain the fuel to a level below the fuel fill hose. Refer to Fuel Tank Draining .

    3. Object Number: 853731 Size: SH
  3. Remove the fuel filler housing to body screws (1) and retainer (2).

    4. Object Number: 300318 Size: SH
  4. Remove the fuel tank filler housing to fuel tank fill pipe screws.
  5. Remove the fuel tank filler housing from the vehicle.
  6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    7. Object Number: 853726 Size: SH
  7. Remove the fuel pipe ground strap bolt.
  8. Separate the ground straps (1, 2).

    9. Object Number: 856636 Size: SH
  9. Remove the rear axle vent hose from the retaining clip (2).

    10. Object Number: 853740 Size: SH
  10. Loosen the fuel tank fill pipe clamp at the rear tank.
  11. Loosen the vent hose clamp at the rear tank.
  12. Separate the fill pipe from the rear tank.
  13. Separate the vent hose from the rear tank.
  14. Remove the fuel fill pipe.
  15. Cap the open end of the fuel tank to prevent system contamination.

Installation Procedure

    Object Number: 853740 Size: SH
  1. Uncap the fuel tank.
  2. Install the fuel fill pipe.
  3. Connect the vent hose to the rear tank.
  4. Connect the fill pipe to the rear tank.
  5. Tighten the vent hose clamp at the rear tank.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Tighten the fuel tank fill pipe clamp at the rear tank.

    7. Tighten
    Tighten the clamps to 2.5 N·m (22 lb in).


    Object Number: 856636 Size: SH
  7. Install the rear axle vent hose to the retaining clip (2).

    8. Object Number: 853726 Size: SH
  8. Position the ground straps (1, 2).
  9. Install the fuel pipe ground strap bolt.

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

  10. Lower the vehicle.

    11. Object Number: 300318 Size: SH
  11. Install the fuel tank filler housing to the vehicle.
  12. Install the fuel tank filler housing to fuel tank fill pipe screws.

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


    Object Number: 853731 Size: SH
  13. Install the fuel tank filler housing to body screws (1) and retainer (2).

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


    Object Number: 300314 Size: SH
  14. If necessary, fill the fuel system.
  15. Install the fuel fill cap.