2005 Chevrolet Avalanche 2500FACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Fuel Fill Hose
    GM1224382Courtesy of GENERAL MOTORS CORP.
  1. Remove the cap from the open end of the front fuel tank.
  2. Install the fuel fill hose/pipe assembly.
  3. Install the fill hose to the front tank.
  4. Connect the fuel fill hose vent line quick connect fitting to the tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Tighten the fuel tank fill hose clamp at the front tank.

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

    6. Fig 2: View Of Rear Axle Vent Hose & Clip
    GM1238176Courtesy of GENERAL MOTORS CORP.
  6. Install the rear axle vent hose to the retaining clip and close the clip.
    7. Fig 3: View Of Ground Wire & Fill Pipe Ground Strap
    GM1224385Courtesy of GENERAL MOTORS CORP.
  7. Position the ground wire and fill pipe ground strap.
  8. Install the ground wire harness bolt.

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

  9. Install the rear fuel tank. Refer to Fuel Tank Replacement (Front Tank)  or Fuel Tank Replacement (Rear Tank) .
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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.