GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 GMC_Truck 🢒 2001 🢒 Jimmy - 4WD 🢒 Engine 🢒 Engine Controls - 4.3L 🢒 Filler Tube Replacement

Filler Tube Replacement Pickup

Removal Procedure

    Object Number: 617004 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Remove the fuel filler cap.
  3. Remove the fuel filler pipe to fill pipe housing attaching screws.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Position an approved gasoline drain container under the fuel filler pipe.

    6. Object Number: 616694 Size: SH
  6. Disconnect the filler pipe ground strap (3).

    7. Object Number: 616679 Size: SH
  7. Wipe the vent hose connection and then loosen the vent hose clamp (2).
  8. Wipe the fuel filler hose connection and then loosen the fuel filler hose clamp (4).
  9. Remove the fuel filler pipe.
  10. Cap the fuel filler hose and the vent hose in order to prevent possible fuel system contamination.

Installation Procedure

    Object Number: 616679 Size: SH
  1. Remove the caps from the fuel filler hose and the vent hose.
  2. Install the fuel filler pipe to the fuel tank fill and vent hoses and the fill pipe housing.
  3. Align the fuel filler pipe with the filler pipe housing.

    4. 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.

    Tighten

        • Tighten the vent hose clamp (2) to 1.7 N·m (15 lb in).
        • Tighten the fuel fill hose clamp (4) to 2.5 N·m (22 lb in).

    Object Number: 616694 Size: SH
  4. Connect the filler pipe ground strap (3) to the frame with the bolt and washer.

    5. Tighten
    Tighten the ground strap bolt to 15 N·m (11 lb ft).

  5. Lower the vehicle.

    6. Object Number: 617004 Size: SH
  6. Install the fuel filler pipe to fill pipe housing attaching screws.

    7. Tighten
    Tighten the fuel filler pipe to fill pipe housing screws to 1.9 N·m (17 lb in).

  7. Install the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks.

Filler Tube Replacement 2-Door Utility

Removal Procedure

    Object Number: 617013 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Raise the vehicle.
  4. Wipe the vent hose connection at the fuel tank and then disconnect the vent hose and clamp (1).
  5. Wipe the fuel filler hose connection at the fuel tank and then disconnect the fuel filler hose and clamp (2).

    6. Object Number: 617017 Size: SH
  6. Remove the filler pipe ground strap bolt (4).

    7. Object Number: 617004 Size: SH
  7. Remove the fuel fill pipe to fill pipe housing attaching screws.
  8. Remove the fuel fill and vent pipes and hoses.

Installation Procedure

    Object Number: 617013 Size: SH

    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.

  1. Install the fuel fill and vent pipes and hoses to the fuel tank and the fill pipe housing.

    2. Tighten

        • Tighten the vent hose clamp (1) to 1.7 N·m (15 lb in).
        • Tighten the fuel fill hose clamp (2) to 2.5 N·m (22 lb in).

    Object Number: 617017 Size: SH
  2. Connect the fill pipe ground strap to the frame with the bolt (4) and washer (3).

    3. Tighten
    Tighten the ground strap bolt to 15 N·m (11 lb ft).

  3. Lower the vehicle.

    4. Object Number: 617004 Size: SH
  4. Install the fuel fill pipe to fill pipe housing attaching screws.

    5. Tighten
    Tighten the fuel fill pipe to fill pipe housing screws to 1.9 N·m (17 lb in).

  5. Install the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks.

Filler Tube Replacement 4-Door Utility Lower

Removal Procedure
  1. Drain the fuel from the fuel tank, leaving the lower fuel fill hose disconnected.
  2. Remove the spare tire (underbody mounted spare tire only).

    3. Object Number: 748093 Size: SH
  3. Loosen the upper fuel fill hose clamp (7).
  4. Disconnect the ground wire (5) from the frame crossover.
  5. Remove the ground wire retaining straps (6) from the lower fuel fill tube.

    6. Object Number: 617000 Size: SH
  6. Remove the lower fuel fill tube retaining bolt from the frame crossover.

    7. Object Number: 748093 Size: SH
  7. Disconnect the lower fuel fill tube (12) from the upper fuel fill hose (11).
  8. Remove the fuel fill tube (12).

Installation Procedure

    Object Number: 748093 Size: SH
  1. Position the fuel fill tube (12) over the frame crossover.
  2. Connect both the upper (11) and lower (13) fuel fill hoses to the lower fuel fill tube (12).

    3. Object Number: 617000 Size: SH

    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.

  3. Install the lower fuel fill tube retaining bolt to the frame crossover.

    4. Tighten
    Tighten the fuel fill tube bracket retaining bolt to 15 N·m (11 lb ft).


    Object Number: 748093 Size: SH
  4. Install the ground wire (5) to the frame crossover.

    5. Tighten
    Tighten the ground strap retaining screw to 15 N·m (11 lb ft).

  5. Attach the ground wire to the lower fuel fill tube with new retaining straps (6).
  6. Position the hose clamps (2, 7) on the upper (11) and lower (13) fuel fill hoses.

    7. Tighten
    Tighten the hose clamps (2, 7) to 2.5 N·m (22 lb in).

  7. Install the spare tire (underbody mounted spare tire only).
  8. Lower the vehicle.
  9. Remove the fuel fill cap and refill the fuel tank.
  10. Install the fuel fill cap.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Filler Tube Replacement 4-Door Utility Upper

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the fuel fill cap.

    3. Object Number: 748097 Size: SH
  3. Remove the fuel fill tube to fuel filler pocket retainer screws (2).
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the spare tire (underbody mounted spare tire only).

    6. Object Number: 748093 Size: SH
  6. Disconnect the ground wire (5) from the frame crossover.
  7. Remove the ground wire retaining straps (6) from the lower fuel fill tube and upper fuel fill hose.
  8. Remove the EVAP canister bracket assembly. Refer to Evaporative Emission Canister Replacement .

    9. Object Number: 748097 Size: SH
  9. Loosen the fuel fill hose clamp (4).
  10. Disconnect the fuel fill tube (3) from the fuel fill hose.
  11. Remove the upper fuel fill tube from the vehicle.

Installation Procedure

    Object Number: 748097 Size: SH
  1. Place the upper fuel fill tube (3) in the fuel fill hose and the fuel filler pocket (1).

    2. 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.

  2. Install the fuel fill tube to fuel filler pocket retainer screws (2).

    3. Tighten
    Tighten the fuel fill pipe retaining screws to 1.9 N·m (17 lb in).

  3. Position the fuel fill hose clamp (4) on the fuel fill hose.

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


    Object Number: 748093 Size: SH
  4. Install the ground wire (5) to the frame crossover.

    5. Tighten
    Tighten the ground strap retaining screw to 15 N·m (11 lb ft).

  5. Attach the ground wire to the lower fuel fill tube and upper fuel fill hose with new retaining strips (6).
  6. Install the EVAP canister bracket assembly. Refer to Evaporative Emission Canister Replacement .
  7. Install the spare tire. Use the underbody mounted spare tire only.
  8. Lower the vehicle.
  9. Install the fuel fill cap.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.