Express 3/4 Ton Van V8-4.8L VIN V (2003)
Fuel Filler Hose: Customer Interest
Fuel System - Vehicle Difficult to Fill With Fuel
File In Section: 06 - Engine/Propulsion System
Bulletin No.: 02-06-04-055
Date: November, 2002
TECHNICAL
Subject:
Vehicle is Difficult to Fill with Fuel
(Install Fuel Filler Baffle)
Models:
2003 Chevrolet Express
2003 GMC Savana
Except Vans with Left Side Door and Cutaway, Cube and Cab-Chassis Vans
Condition
Some customers may comment that the vehicle is difficult to fill with fuel.
Correction
Use the following procedure to install a fuel filler baffle.
1.
Place the vehicle in position so it may be lifted.
Caution:
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an
open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
2.
Check the fuel gauge to determine the level of fuel in the tank. If above 7/8th of a tank, some fuel will need to be removed from the fuel tank using
acceptable practices.
Caution:
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. An ignition source may be defined as any
electrical (battery or 110 volt) or pneumatic tool. Have a dry chemical (Class B) fire extinguisher nearby.
3.
Open the fuel fill door and remove the two screws and the push pin that retain the fuel filler neck to the sheet metal of the body.
4.
Remove the fuel filler (gas) cap from the fuel fill pipe.
5.
Raise the vehicle.
6.
With a hand driver and socket, loosen the clamps that retain the hose to the fuel fill pipe and the fuel tank inlet.
7.
Remove the fuel tank tube ground strap to vehicle attaching screw.
Notice:
To ease the removal of the fuel fill pipe, carefully slit the hose with a utility knife, being sure not to nick or scratch the fuel fill pipe surface.
8.
Slit the fuel fill pipe end of the hose and remove the fuel fill pipe.
9.
Remove the hose from the fuel tank inlet.
10.
Remove the clamps from the hose. They will be used on the new hose assembly.
Caution:
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. An ignition source may be defined as any
electrical (battery or 110 volt) or pneumatic tool. Have a dry chemical (Class B) fire extinguisher nearby.
11.
Insert the fuel filler baffle into the fuel tank inlet, non-barbed end first. With the aid of a small clean piece of wood and your hand, position the fuel
filler baffle into the fuel tank so the outboard end of the baffle is flush with the end of the opening.
