Vehicle is Difficult to Fill with Fuel (Install Fuel Filler Baffle)

Some customers may comment that the vehicle is difficult to fill with fuel.

Use the following procedure to install a fuel filler baffle.

1. Place the vehicle in position so it may be lifted.

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

2. Check the fuel gauge to determine the level of fuel in the tank. If above 7/8th of a tank, some fuel will need to be removed from the fuel tank using acceptable practices.

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. An ignition source may be defined as any electrical (battery or 110 volt) or pneumatic tool. Have a dry chemical (Class B) fire extinguisher nearby.

3. Open the fuel fill door and remove the two screws and the push pin that retain the fuel filler neck to the sheet metal of the body.
4. Remove the fuel filler (gas) cap from the fuel fill pipe.
5. Raise the vehicle.
6. With a hand driver and socket, loosen the clamps that retain the hose to the fuel fill pipe and the fuel tank inlet.
7. Remove the fuel tank tube ground strap to vehicle attaching screw.

Notice: To ease the removal of the fuel fill pipe, carefully slit the hose with a utility knife, being sure not to nick or scratch the fuel fill pipe surface.

8. Slit the fuel fill pipe end of the hose and remove the fuel fill pipe.
9. Remove the hose from the fuel tank inlet.
10. Remove the clamps from the hose. They will be used on the new hose assembly.

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. An ignition source may be defined as any electrical (battery or 110 volt) or pneumatic tool. Have a dry chemical (Class B) fire extinguisher nearby.

11. Insert the fuel filler baffle into the fuel tank inlet, non-barbed end first. With the aid of a small clean piece of wood and your hand, position the fuel filler baffle into the fuel tank so the outboard end of the baffle is flush with the end of the opening.
12. Install the notched end of the hose, with the clamp in position, to the fuel tank inlet. Position the notch in the hose around the tab on the top of the fuel tank inlet.
13. Install the fuel tank inlet pipe into the hose and clamp assembly, and position into the body sheet metal opening.
14. Tighten both hose clamps.

Tighten
Tighten the two fuel fill hose clamps to 2.75 N·m (24 lb in).

15. Install the ground strap bolt.

Tighten
Tighten the ground strap bolt to 2.75 N·m (24 lb in).

16. Lower the vehicle.
17. Reinstall the fuel (gas) cap.
18. Reinstall the two pocket retaining screws and the one push pin.

Tighten
Tighten the two pocket retaining screws to 2.75 N·m (24 lb in).

19. Close the fuel filler door.

Parts are expected to be available November 8, 2002 from GMSPO.

For vehicles repaired under warranty, use: