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HOMESERVICE MANUALSCHEVROLET2009TAHOE BASE, 4.8 CREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 276 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - HYBRID (LZ1) - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL TANK FILLER PIPE REPLACEMENTINSTALLATION PROCEDURE
2009 Chevrolet Tahoe Base, 4.8 C

Installation Procedure

2009 Chevrolet Tahoe Base, 4.8 CSECTION Installation Procedure
WARNING: This page is about a different car, the 2010 GMC Yukon, 2010 Chevrolet Tahoe, and 2010 Cadillac Escalade. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Fill Pipe Retainer, Bracket Bolts & Quick Connect Fitting
    GM1964116Courtesy of GENERAL MOTORS CORP.
  1. Remove the caps from the fuel tank opening and the EVAP vent line.
  2. Install the fuel fill hose to the fuel tank. Ensure that the notch in the hose is aligned with the notch on the fuel tank.
  3. Install the fuel fill pipe vent hose to the fuel tank vent valve.
  4. Install the tab (1) on the fuel fill pipe to the notch in the frame.
  5. Install the fuel fill pipe bracket bolts (2, 4).

    Tighten:  Tighten the bolt to 12 N.m (106 lb in).

  6. Connect the fuel fill pipe vent line quick connect fitting (3) to the EVAP canister vent solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service .
    7. Fig 2: View Of Fuel Vent Hose Clamp & Fuel Filler Hose Clamp
    GM1964118Courtesy of GENERAL MOTORS CORP.
  7. Tighten the fuel fill hose clamp (1).

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

  8. Tighten the fuel fill pipe vent hose clamp (2) at the fuel tank vent valve.

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

    9. Fig 3: View Of Fill Pipe Ground Strap, Lamp Ground Wires & Harness Ground Bolts
    GM1704587Courtesy of GENERAL MOTORS CORP.
  9. Position the fill pipe ground strap (5) to the left rear lamp ground wire (4).
  10. Install the rear lamp ground wire (4) and ground strap (5) to the frame. Insert the lamp ground wire anti-rotation tab into the hole in the frame.
  11. Install the chassis wiring harness ground bolt.

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

    12. Fig 4: View Of Rear Axle Vent Hose Clip
    GM1704586Courtesy of GENERAL MOTORS CORP.
  12. If necessary, install the air suspension hose at the fill pipe.
  13. Install the rear axle vent hose clip (1) to the fill pipe.
  14. Lower the vehicle.
    15. Fig 5: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  15. 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).

    16. Fig 6: View Of Spare Tire & Stowage Lock Cylinder
    GM1704585Courtesy of GENERAL MOTORS CORP.
  16. Install the spare tire, if necessary.
  17. Install the spare tire stowage lock cylinder, if necessary.
    18. Fig 7: View Of Filler Door And Tethered Fuel Filler Cap
    GM300314Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel fill cap.
RENDER: 1.0x

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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.