2005 Chevrolet Avalanche 2500FACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  1. Remove the caps from the fuel and EVAP lines.
  2. Install the fuel and EVAP intermediate lines.
  3. Connect the fuel and EVAP intermediate lines to the rear tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    4. Fig 2: View Of Fuel Tank & Straps
    GM1224381Courtesy of GENERAL MOTORS CORP.
  4. With the aid of an assistant, completely raise the rear tank.
  5. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

  7. Remove the adjustable jack from under the fuel tank.
    8. Fig 3: View Of Fuel Pressure Sensor Electrical Connector
    GM1372719Courtesy of GENERAL MOTORS CORP.
  8. Connect the fuel pressure sensor electrical connector (1).
    9. Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1372710Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    10. Fig 5: View Of EVAP Canister & Quick Connect Fittings
    GM1372543Courtesy of GENERAL MOTORS CORP.
  10. Connect the EVAP canister quick connect fittings. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    11. Fig 6: View Of Spare Tire Hoist Crossmember & Bolts
    GM871929Courtesy of GENERAL MOTORS CORP.
  11. Install the spare tire hoist crossmember and bolts.

    Tighten:  Tighten the bolts to 50 N.m (37 lb ft).

    12. Fig 7: View Of Spare Tire
    GM385791Courtesy of GENERAL MOTORS CORP.
  12. Install the rear exhaust insulator.
  13. Install the spare tire.
    14. Fig 8: Locating Spare Tire
    GM385766Courtesy of GENERAL MOTORS CORP.
  14. Install the spare tire stowage lock cylinder.
    15. Fig 9: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel tank filler housing.
  16. Install the fuel tank filler housing to fuel tank fill pipe bolts.

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

    17. Fig 10: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2).

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

  18. Refill the fuel tank.
  19. Install the fuel fill cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  21. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
Factory Service Tools

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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.

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