GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Silverado - 2WD 🢒 Engine 🢒 Engine Controls and Fuel - 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L 🢒 Fuel Tank Filler Pipe Replacement

Fuel Tank Filler Pipe Replacement 25 Ext/Crew Cab w/26 Gal Tank

Removal Procedure

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

    2. Object Number: 300318 Size: SH
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle.

    5. Object Number: 1852221 Size: SH
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).

    8. Object Number: 1852229 Size: SH
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.

    10. Object Number: 1852233 Size: SH
  10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service.
  11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

    Object Number: 1852233 Size: SH
  1. Remove the cap from the opening on the fuel tank.
  2. Position the fuel tank fill pipe.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank.

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

  4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service.

    5. Object Number: 1852229 Size: SH
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Close the axle vent hose clip.

    7. Object Number: 1852221 Size: SH
  7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  9. Install the fuel tank fill pipe ground wire bolt (3).

    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.
  12. Install the fuel tank filler housing to fuel tank fill pipe bolts.

    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 TORX® screws (1) and pushpin retainer (2).

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

Fuel Tank Filler Pipe Replacement 15 Reg Cab w/26 Gal Tank

Removal Procedure

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

    2. Object Number: 300318 Size: SH
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle.

    5. Object Number: 1852221 Size: SH
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).

    8. Object Number: 1852229 Size: SH
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.

    10. Object Number: 1852233 Size: SH
  10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service.
  11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

    Object Number: 1852233 Size: SH
  1. Remove the cap from the opening on the fuel tank.
  2. Position the fuel tank fill pipe.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank.

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

  4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service.

    5. Object Number: 1852229 Size: SH
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Close the axle vent hose clip.

    7. Object Number: 1852221 Size: SH
  7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  9. Install the fuel tank fill pipe ground wire bolt (3).

    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.
  12. Install the fuel tank filler housing to fuel tank fill pipe bolts.

    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 TORX® screws (1) and pushpin retainer (2).

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

Fuel Tank Filler Pipe Replacement 15/25 Reg/Ext/Crew cab w/34 Gal Tank

Removal Procedure

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

    2. Object Number: 300318 Size: SH
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.

    5. Object Number: 1852221 Size: SH
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).

    8. Object Number: 1852343 Size: SH
  8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
  9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  10. Remove the fuel tank fill pipe.
  11. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

    Object Number: 1852343 Size: SH
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

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


    Object Number: 1852221 Size: SH
  5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  7. Install the fuel tank fill pipe ground wire bolt (3).

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


    Object Number: 300318 Size: SH
  8. Lower the vehicle.
  9. Install the fuel tank filler housing.
  10. Install the fuel tank filler housing to fuel tank fill pipe bolts.

    11. Tighten
    Tighten the bolts to 2.3 N·m (20 lb in).


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

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

Fuel Tank Filler Pipe Replacement 35 Reg/Ext/Crew Cab w/34 Gal Tank

Removal Procedure

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

    2. Object Number: 300318 Size: SH
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Partially raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.

    5. Object Number: 1852221 Size: SH
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).

    8. Object Number: 1852343 Size: SH
  8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
  9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  10. Remove the fuel tank fill pipe.
  11. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

    Object Number: 1852343 Size: SH
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.

    3. Caution: Refer to Fastener Caution in the Preface section.

  3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
  4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

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


    Object Number: 1852221 Size: SH
  5. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  6. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  7. Install the fuel tank fill pipe ground wire bolt (3).

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


    Object Number: 300318 Size: SH
  8. Lower the vehicle.
  9. Install the fuel tank filler housing.
  10. Install the fuel tank filler housing to fuel tank fill pipe bolts.

    11. Tighten
    Tighten the bolts to 2.3 N·m (20 lb in).


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

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

Fuel Tank Filler Pipe Replacement 15 Ext/Crew Cab w/26 Gal Tank

Removal Procedure

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

    2. Object Number: 300318 Size: SH
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle.

    5. Object Number: 1852269 Size: SH
  5. Remove the fuel tank fill pipe ground wire bolt.
  6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire.

    8. Object Number: 1852229 Size: SH
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.

    10. Object Number: 1852270 Size: SH
  10. If equipped with 5 ft 8 in. bed, perform the following steps:
  11. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service.
  12. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  13. Remove the fuel tank fill pipe.
  14. Cap the opening on the fuel tank in order to prevent possible system contamination.

    15. Object Number: 1853549 Size: SH
  15. If equipped with 6 ft 5 in. bed, perform the following steps:
  16. Disconnect the fuel tank EVAP line quick connect fitting (1) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service.
  17. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
  18. Remove the fuel tank fill pipe.
  19. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

    Object Number: 1853549 Size: SH
  1. If equipped with 6 ft 5 in. bed, perform the following steps:
  2. Remove the cap from the opening on the fuel tank.
  3. Position the fuel tank fill pipe.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

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

  5. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (1). Refer to Plastic Collar Quick Connect Fitting Service.

    6. Object Number: 1852270 Size: SH
  6. If equipped with 5 ft 8 in. bed, perform the following steps:
  7. Remove the cap from the opening on the fuel tank.
  8. Position the fuel tank fill pipe.
  9. Tighten the fuel tank fill pipe clamp (1) at the fuel tank.

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

  10. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service.

    11. Object Number: 1852229 Size: SH
  11. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  12. Close the axle vent hose clip.

    13. Object Number: 1852269 Size: SH
  13. Position the fuel tank fill pipe ground wire to the frame bracket.
  14. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole.
  15. Install the fuel tank fill pipe ground wire bolt.

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

  16. Lower the vehicle.

    17. Object Number: 300318 Size: SH
  17. Install the fuel tank filler housing.
  18. Install the fuel tank filler housing to fuel tank fill pipe bolts.

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


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

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