Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

2004 Chevrolet Avalanche 2500FACTORY OEM SERVICE PROCEDURE

Removal Procedure

IMPORTANT: Clean all fuel and evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

Fig 1: View Of Fuel Fill Hose

GM1224382

Courtesy of GENERAL MOTORS CORP.

Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Front Tank) or Fuel Tank Draining Procedure (Rear Tank) .
Disconnect the EVAP vent line from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 2: View Of Vapor Line At Fuel Tank

GM1372488

Courtesy of GENERAL MOTORS CORP.

Disconnect the vapor line (1) from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 3: View Of Fuel Feed & EVAP Lines At Fuel Tank

GM1372476

Courtesy of GENERAL MOTORS CORP.

Disconnect the fuel feed and EVAP lines from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank

GM1224396

Courtesy of GENERAL MOTORS CORP.

Open the clip on the side of the fuel tank retaining the intermediate lines.
Disconnect the fuel and EVAP intermediate lines from the front tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.

Fig 5: View Of Fuel Tank Shield (Front Tank)

GM856641

Courtesy of GENERAL MOTORS CORP.

If equipped, remove the fuel tank shield bolts.
If equipped, remove the fuel tank shield.

Fig 6: View Of Fuel Tank & Straps (Front Tank)

GM1224378

Courtesy of GENERAL MOTORS CORP.

Factory Service Tools

Use the Manual With the Right Hardware

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.