Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose)

This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 -- Engine/Propulsion System).

This bulletin provides information on two different conditions.

Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full.

This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition.

Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out.

This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off.

Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below.

1. Remove the fuel fill cap.
2. Remove the fuel fill pipe housing.



3. Remove the fuel fill pipe bracket nut (2).
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual (SI Document ID #744862).
5. Remove the fuel fill pipe ground strap bolt.
6. Cut off the ground strap ring terminal and tie strap.



7. Loosen the fuel hose clamp (8).
8. Remove the fuel fill upper pipe (7) from the vehicle.
9. Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles.
10. Tighten the fuel hose clamp.

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

11. Wrap the excess length of ground strap around the fuel hose as necessary.
12. Install the fuel fill pipe ground strap bolt in its original location.
13. Loosen the fuel hose clamps (1,3).
14. Remove the lower fuel hose (2) from the vehicle.
15. Install the new lower fuel hose into the vehicle.
16. Tighten the lower fuel hose clamps.

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

17. Lower the vehicle.
18. Install the fuel fill pipe bracket nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).

19. Install the fuel fill pipe housing.
20. Install the fuel fill cap.

Parts are expected to be available from GMSPO on August 13, 2004.

For vehicles repaired under warranty, use:

*This is a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide.