2005 Chevrolet Avalanche 2500FACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Sending Unit Electrical Connector (Front Tank)
    GM1238171Courtesy of GENERAL MOTORS CORP.
  1. If necessary, install the sending unit. Refer to Fuel Sender Assembly Replacement (Front Tank)  or Fuel Sender Assembly Replacement (Rear Tank) .
  2. Place the fuel tank onto a suitable jack.
  3. With the aid of an assistant, partially raise the fuel tank.
  4. Connect the sending unit electrical connector.
  5. Engage the CPA retainer.
    6. Fig 2: View Of Fuel Tank & Straps (Front Tank)
    GM1224378Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, completely raise the fuel tank.
  7. Install the fuel tank straps.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the fuel tank strap bolts.

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

  9. Remove the adjustable jack from under the fuel tank.
    10. Fig 3: View Of Fuel Tank Shield (Front Tank)
    GM856641Courtesy of GENERAL MOTORS CORP.
  10. If equipped, install the fuel tank shield.
  11. If equipped, install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 15 N.m (11 lb ft).

    12. Fig 4: View Of Fuel & EVAP Intermediate Lines At Fuel Tank
    GM1224396Courtesy of GENERAL MOTORS CORP.
  12. Remove the caps from the fuel and EVAP lines.
  13. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Close the clip on the side of the fuel tank retaining the intermediate lines.
    15. Fig 5: View Of Fuel Feed & EVAP Lines At Fuel Tank
    GM1372476Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel feed and EVAP lines to the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    16. Fig 6: View Of Vapor Line At Fuel Tank
    GM1372488Courtesy of GENERAL MOTORS CORP.
  16. Connect the vapor line (1) to the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    17. Fig 7: View Of Fuel Fill Hose
    GM1224382Courtesy of GENERAL MOTORS CORP.
  17. Connect the EVAP vent line to the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  18. Install the fuel fill hose to the fuel tank.
  19. Tighten the fuel fill hose clamp at the fuel tank.

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

  20. Lower the vehicle.
  21. Refill the fuel tank.
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  24. 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

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.