Refueling problem

[roberson104]

I have a 2004 Trailblazer, once or twice a week when i try to refuel, the gas just backs up and flows out, it will eventually drain down, but it seems the tank is pushing a small amount of gas back out of the opening also. I know the tank is not full because i can wait about a hour or two and then it will allow me to refill the tank. any body else had this problem, I am a avid mechanic but this has me stumped.

[GM-Tech]

Subject: Vehicle is Difficult to Fill with Fuel or Filling Station Pump Shuts Off Before Tank is Full or Fuel Spits Back/Out When Filling Tank (Replace Fuel Tank Filler Upper Pipe and Lower Hose) #04-06-04-003A - (08/11/2004)

 

 

Models: 2003 Chevrolet TrailBlazer with 83 L (22 Gallon) Fuel Tank (RPO NNK)

 

2003 GMC Envoy with 83 L (22 Gallon) Fuel Tank (RPO NNK)

 

2003 Oldsmobile Bravada with 83 L (22 Gallon) Fuel Tank (RPO NNK)

 

2002-2003 Chevrolet TrailBlazer EXT

 

2002-2003 GMC Envoy XL

 

2004 Buick Rainier

 

2004 Chevrolet TrailBlazer, TrailBlazer EXT

 

2004 GMC Envoy, Envoy XL, Envoy XUV

 

2004 Oldsmobile Bravada

 

Built Prior to December 2003

 

 

 

 

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This bulletin is being revised to provide new part number for 2002-2003 vehicles. Please discard Corporate Bulletin Number 04-06-04-003 (Section 06 -- Engine/Propulsion System).

 

 

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This bulletin provides information on two different conditions.

 

Condition 1

Some customers may comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full.

 

Cause

This condition may be caused by the variability (fuel flow rates, type of fuel fill nozzle, fuel properties) at the filling stations. There is a potential to develop an increase in back pressures internal to the fuel fill neck. This back pressure trips the fuel nozzle prior to filling the tank, or results in a hard to fill condition.

 

Condition 2

Some customers may comment that when filling the fuel tank, a small amount of fuel may spit back/out.

 

Cause

This condition may be caused by the equalization of pressure between the fuel tank and the fuel fill neck that does not react quickly to the variance in the pressure when the fueling station fuel nozzle trips off.

 

Correction

Replace the fuel tank filler upper pipe assembly with P/N 88983256 or P/N 15131043, and lower hose assembly with P/N 15131046. The new upper pipe has been redesigned to provide smoother flow conditions within the section and the lower hose has been redesigned to include a checking feature. Use the procedure listed below.

 

Remove the fuel fill cap.

Remove the fuel fill pipe housing.

 

 

 

Remove the fuel fill pipe bracket nut (2).

Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual (SI Document ID #744862).

Remove the fuel fill pipe ground strap bolt.

Cut off the ground strap ring terminal and tie strap.

 

 

 

Loosen the fuel hose clamp (8).

Remove the fuel fill upper pipe (7) from the vehicle.

Install the new fuel fill upper pipe into the vehicle. Use P/N 88983256 for 2002-2003 model year vehicles or P/N 15131043 for 2004 model year vehicles.

Tighten the fuel hose clamp.

Tighten

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

 

Wrap the excess length of ground strap around the fuel hose as necessary.

Install the fuel fill pipe ground strap bolt in its original location.

Loosen the fuel hose clamps (1,3).

Remove the lower fuel hose (2) from the vehicle.

Install the new lower fuel hose into the vehicle.

Tighten the lower fuel hose clamps.

Tighten

Tighten the clamps to 2.5 N·m (22 lb in).

 

Lower the vehicle.

Install the fuel fill pipe bracket nut.

Tighten

Tighten the nut to 10 N·m (89 lb in).

 

Install the fuel fill pipe housing.

Install the fuel fill cap.

Parts Information

Part Number

Description

Qty

 

88983256

Pipe Asm - F/Tank Fill (2002-2003 vehicles)

1

 

15131043

Pipe Asm - F/Tank Fill (2004 vehicles)

1

 

15131046

Hose - F/Tank Fill

1

 

 

Parts are expected to be available from GMSPO on August 13, 2004.

 

Warranty Information

For vehicles repaired under warranty, use:

 

Labor Operation

Description

Labor Time

 

L9701*

Fuel Tank Filler Upper Pipe and Lower Hose - Replace

0.5 hr

 

 

*This is a unique labor operation number for use only with this bulletin. This number will not be published in the Labor Time Guide.

 

 

 

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.

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