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Engine Controls/fuel - 4.3l - Repair Instructions GMC Sierra 2500

Testing & Diagnostics 3 illustrations ~19600 words

Engine Control Module Replacement

CAUTIONTurn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. The replacement control module must be programmed.

Note. Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References .

Removal Procedure

  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM.
  4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM.
  5. Disengage the retainer tabs securing the ECM to the bracket.
  6. Remove the ECM.

Installation Procedure

  1. Install the bottom ECM tabs into the bracket.
  2. Push the ECM in securing the ECM to the bracket.
  3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM.
  4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM.
  5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  6. If a NEW ECM was installed, program the ECM. Refer to «Control Module References»(/gmc/sierra-2500/2012-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

Crankshaft Position System Variation Learn

Note. The Crankshaft Position System Variation Learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: A crankshaft position sensor replacement An engine control module (ECM) replacement An engine replacement A crankshaft balancer replacement A crankshaft replacement Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship.

Note. The ECM monitors certain component signals to determine if all the conditions are met to continue with the Crankshaft Position System Variation Learn Procedure.

  1. Ignition ON, observe the DTC information with a scan tool. Verify no other DTCs are set, except DTCs P0300-P0306, or P0315. If DTCs are set, except DTCs P0300-P0306, or P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/gmc/sierra-2500/2012-2012/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for further diagnosis.
  2. Select the Crankshaft Pos. Variation Learn procedure with a scan tool.
  3. The scan tool instructs you to perform the following: Block drive wheels. Set parking brake. Cycle the ignition. Apply and hold brake pedal. NOTE: The vehicle must remain in PARK/NEUTRAL. Start and idle the engine.
  4. Enable the CKP System Variation Learn Procedure with a scan tool.
  5. Accelerate to wide open throttle (WOT) and release the throttle when fuel cut-off occurs.
  6. Test in progress.
  7. The scan tool displays Learn Status: Learned this ignition.
  8. Once the Learn Procedure has successfully completed, and in order to store the crankshaft position system variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes.

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

Reset Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
  2. Ignition ON, engine OFF.
  3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Learn Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
  2. The engine speed is between 450-4, 000 RPM.
  3. The manifold absolute pressure (MAP) is greater than 5 kPa.
  4. The mass air flow (MAF) is greater than 2 g/s.
  5. The ignition voltage is greater than 10 volts.

Throttle Learn

Reset Procedure (Performed after the throttle body is cleaned or replaced)

  1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool.
  2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed.
  3. Clear the DTCs and return to the diagnostic that referred you here.

Learn Procedure (Performed after the ECM is flashed or replaced)

  1. Start and idle the engine for 3 minutes.
  2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed.
  3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease.
  4. Ignition OFF for 60 seconds.
  5. Start and idle the engine for 3 minutes.
  6. After the 3 minute run time the engine should be idling normal. NOTE: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
  7. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
  8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

Throttle Body Cleaning

  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Inspect the throttle body bore and throttle plate for deposits. You need to open the throttle plate in order to inspect all surfaces.
  3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 (Canadian P/N 993026), or ACDelco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Perform the Throttle/Idle Learn procedure. Refer to «Throttle/Idle Learn»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac-n-fill) , «Cooling System Draining and Filling (Static Fill)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) , «Cooling System Draining and Filling (Vac-N-Fill Diesel)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac-n-fill) .
  2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2).
  3. Remove the ECT sensor from the cylinder head.
CAUTIONReplacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
CAUTIONUse care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
  1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent.
  2. Install the ECT sensor to the cylinder head. Tighten Tighten the sensor to 20 N.m (15 lb ft).
  3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2).
  4. Fill the cooling system. Refer to «Cooling System Draining and Filling (Vac-N-Fill Gasoline)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac-n-fill) , «Cooling System Draining and Filling (Static Fill)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-static) , «Cooling System Draining and Filling (Vac-N-Fill Diesel)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac-n-fill) .

Scheme 127

Scheme 127: Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Scheme 127: Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
CalloutComponent Name
1Mass Airflow Sensor Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 1.5 (13 lb in)
2Mass Airflow Sensor/Intake Air Temperature Sensor Procedure Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Mass Airflow Sensor with Intake Air Temperature Sensor Replacement

  1. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  2. Remove the MAP sensor bolt (1).
  3. Using a slight rocking motion while pulling straight up, remove the MAP sensor (2) from the upper intake manifold.
  4. Inspect the MAP sensor seal for damage, replace the seal if necessary.
  1. Install a NEW MAP sensor seal to the MAP sensor, if necessary.
  2. Install the MAP sensor (2) to the upper intake manifold.
  3. Install the MAP sensor bolt (1). Tighten Tighten the bolt to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. If vehicle is a 2-wheel drive (2WD) perform the following steps, otherwise proceed to step 5.
  3. Disconnect the connector position assurance (CPA) retainer.
  4. Disconnect the HO2S pigtail electrical connector (7) from the engine wiring harness electrical connector (6).
  5. If vehicle is a 4-wheel drive (4WD) perform the following steps, disconnect the CPA retainer.
  6. Disconnect the engine wiring harness electrical connector (7) from the HO2S pigtail electrical connector (8).
  7. Remove the HO2S pigtail electrical connector clip (9) from the fuel line bracket.
  8. Remove the HO2S (1).

Note. A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (1). Tighten Tighten the sensor to 42 N.m (31 lb ft).
  3. If vehicle is a 4WD perform the following steps otherwise proceed to step 7.
  4. Install the HO2S pigtail electrical connector clip (9) to the fuel line bracket.
  5. Connect the engine wiring harness electrical connector (7) to the HO2S pigtail electrical connector (8).
  6. Connect the CPA retainer.
  7. If vehicle is a 2WD perform the following steps, connect the HO2S pigtail electrical connector (7) to the engine wiring harness electrical connector (6).
  8. Connect the CPA retainer.
  9. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Disconnect the connector position assurance (CPA) retainer.
  3. Disconnect the engine wiring harness electrical connector (1) from the HO2S pigtail electrical connector.
  4. Remove the HO2S pigtail electrical connector clip (2) from the frame.
  5. Remove the HO2S (4).

Note. A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.

  1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (4). Tighten Tighten the sensor to 42 N.m (31 lb ft).
  3. Install the HO2S pigtail electrical connector clip (2) to the frame.
  4. Connect the engine wiring harness electrical connector (1) to the HO2S pigtail electrical connector.
  5. Connect the CPA retainer.
  6. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the HO2S pigtail electrical connector (5) from the engine wiring harness electrical connector (4).
  4. Remove the HO2S (2).
  1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (2). Tighten Tighten the sensor to 42 N.m (31 lb ft).
  3. Connect the HO2S pigtail electrical connector (5) to the engine wiring harness electrical connector (4).
  4. Install the CPA retainer.
  5. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the engine wiring harness electrical connector (2) from the HO2S pigtail electrical connector (1).
  4. Remove the HO2S pigtail electrical connector clip from the engine wiring harness clip (3).
  5. Remove the HO2S (3).
  1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
  2. Install the HO2S (3). Tighten Tighten the sensor to 42 N.m (31 lb ft).
  3. Install the HO2S pigtail electrical connector clip to the engine wiring harness clip (3).
  4. Connect the engine wiring harness electrical connector (2) to the HO2S pigtail electrical connector (1).
  5. Install the CPA retainer.
  6. Lower the vehicle.
  1. Remove the knee bolster. Refer to «Knee Bolster Replacement (With RPO SLT)»(/gmc/sierra-2500/2012-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) , «Knee Bolster Replacement (Without RPO SLT)»(/gmc/sierra-2500/2012-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
  2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1).
  3. Remove the accelerator pedal bolts.
  4. Remove the accelerator pedal.
  1. Position the accelerator pedal to the accelerator pedal bracket.
  2. Install the accelerator pedal bolts. Tighten Tighten the bolts to 9 N.m (80 lb in).
  3. Connect the APP sensor electrical connector (1).
  4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range.
  5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  6. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
  7. Install the knee bolster. Refer to «Knee Bolster Replacement (With RPO SLT)»(/gmc/sierra-2500/2012-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) , «Knee Bolster Replacement (Without RPO SLT)»(/gmc/sierra-2500/2012-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
  1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (2) from the throttle body.
  3. Remove the throttle body bolts.
  4. Remove the throttle body and gasket. Discard the gasket.
  1. Install a NEW throttle body gasket into the upper intake manifold.
  2. Place the throttle body onto the upper intake manifold.
  3. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (2) to the throttle body.
  5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  6. Perform the throttle learn procedure. Refer to «Throttle/Idle Learn»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .

Fuel Pressure Relief (CH-48027)

Special Tools

CH-48027 Digital Pressure Gauge

  1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/gmc/sierra-2500/2012-2012/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
  2. Remove the engine cover, if required.
  3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  4. Remove the fuel rail service port cap.
  5. Wrap a shop towel around the fuel rail service port.
  6. Connect the CH-48027-3 (4) to the fuel rail service port.
  7. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
  8. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  10. Close the valve on the CH-48027-2 (2).
  11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  13. Disconnect the CH-48027-3 (4) from the fuel rail service port.
  14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  15. Install the fuel rail service port cap.
  16. Install the engine cover, if required.
  17. Tighten the fuel fill cap.

Fuel Pressure Relief (Without CH-48027)

WARNINGRemove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
  1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/gmc/sierra-2500/2012-2012/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
  2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  3. Remove the engine cover, if required.
  4. Remove the fuel rail service port cap.
  5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve.
  6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  7. Install the fuel rail service port cap.
  8. Install the engine cover, if required.
  9. Tighten the fuel fill cap.

Fuel Pressure Gauge Installation and Removal

Special Tools

CH-48027 Digital Pressure Gauge

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
  3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 digital pressure gauge, refer to the manufacture's directions.
  1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
  3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  4. Disconnect the CH-48027-3 (4) from the fuel rail service port.
  5. Install the fuel rail service port cap.
  6. Install the engine cover, if required.
  7. Tighten the fuel fill cap.

Special Tools

J 41769 Fuel Line Quick Disconnect Tool

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Using compressed air, blow any debris from around the fittings.
  3. Using J 41769 fuel line quick disconnect tool, insert the correct size tool into the female connector, then push inward to release the locking tabs.
  4. Pull the fuel line connection apart.
  5. Using a clean shop towel, wipe off the male pipe end.
  6. Inspect both ends of the fuel line connections for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the fuel line connections together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the fuel line connections to ensure that the connection is secure.

Disconnect Procedure

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Using compressed air, blow any dirt or debris from around the connection.
  3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs.
  4. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
  5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting.
  6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction.
  7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow.
  8. Pull the connection apart.

Connect Procedure

  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.

Fuel Tank Draining

Special Tools

J 45004 Fuel Tank Drain Hose

  1. Remove the fuel filler cap.
  2. Insert J 45004 fuel tank drain hose down the fuel filler tube attached to the appropriate draining devise.
  3. Drain a much fuel as possible.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-draining) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Disconnect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings from the chassis lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  6. Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
  7. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
  10. Remove the chassis wiring harness clip from the fuel tank shield.
  11. Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1).
  12. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
  13. Position and secure the EVAP canister vent solenoid out of the way.
  14. Place a suitable adjustable jack under the fuel tank.
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.
  17. Lower the fuel tank half way.
  18. Disconnect the chassis wiring harness clip at the frame crossmember.
  19. Lower the fuel tank until the electrical connections are accessible.
  20. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
  21. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
  22. Completely lower the fuel tank.
  23. With the aid of an assistant, place the fuel tank in a suitable work area.
  24. Remove the fuel tank shield push on retainers.
  25. Remove the fuel tank shield.
  26. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
  27. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  28. Remove the fuel feed pipe from the fuel tank clip (1).
  29. Remove the EVAP canister purge pipe from the fuel tank clip (1).
  30. Disconnect the EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  31. Remove the EVAP rear pipe from the fuel tank clips (1 and 2).
  32. Disconnect the small EVAP rear pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  33. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  1. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Position and connect the small EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Position and connect the EVAP rear pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Install the EVAP rear pipe to the fuel tank clips (1 and 2).
  5. Install the EVAP canister purge pipe to the fuel tank clip (1).
  6. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Install the fuel feed pipe to the fuel tank clip (1).
  8. Position and install the fuel tank shield.
  9. Install the fuel tank shield push on retainers.
  10. With the aid of an assistant, place the fuel tank in a the adjustable jack.
  11. Raise the fuel tank until the electrical connections can be made.
  12. Connect the chassis wiring harness electrical connector to the fuel tank module.
  13. Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
  14. Completely raise the fuel tank into position.
  15. Install the fuel tank straps.
  16. Install the fuel tank strap bolts. Tighten Tighten the bolts to 40 N.m (30 lb ft).
  17. Remove the adjustable jack from under the fuel tank.
  18. Un-secure and position the EVAP canister vent solenoid to the fuel tank.
  19. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
  20. Ensure that the EVAP canister vent solenoid engages the fuel tank bracket retainer (1).
  21. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  22. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  23. Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
  24. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
  25. Install the chassis wiring harness clip to the fuel tank shield.
  26. Remove the caps from the fuel and EVAP lines.
  27. Connect the fuel tank fuel feed (1) and EVAP (2) line quick connect fittings to the chassis lines. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  28. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  29. Refill the fuel tank.
  30. Install the fuel cap.
  31. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  32. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-draining) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Remove the fuel tank shield bolts, if equipped.
  5. Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
  6. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Disconnect the fuel tank EVAP line quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
  12. Lower the fuel tank half way.
  13. Disconnect the chassis wiring harness clip at the frame crossmember.
  14. Lower the fuel tank until the electrical connections are accessible.
  15. Disconnect the chassis wiring harness electrical connector from the fuel tank pressure sensor.
  16. Disconnect the chassis wiring harness electrical connector from the fuel tank module.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. If replacing the fuel tank proceed to the next step, otherwise proceed to step 10 in the installation procedure.
  20. Remove the fuel tank shield push on retainers.
  21. Remove the fuel tank shield.
  22. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  23. Remove the fuel feed pipe from the fuel tank clips (1).
  24. Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  25. Remove the EVAP pipe from the fuel tank clips (1).
  26. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  27. Remove the EVAP pipe from the fuel tank clips (1 and 2).
  28. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  1. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Install the EVAP pipe to the fuel tank clips (1 and 2).
  4. Position and connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Install the EVAP pipe to the fuel tank clips (1).
  6. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Install the fuel feed pipe to the fuel tank clips (1).
  8. Position and install the fuel tank shield.
  9. Install the fuel tank shield push on retainers.
  10. With the aid of an assistant, place the fuel tank in a the adjustable jack.
  11. Raise the fuel tank until the electrical connections can be made.
  12. Connect the chassis wiring harness electrical connector to the fuel tank module.
  13. Connect the chassis wiring harness electrical connector from the fuel pressure sensor.
  14. Completely raise the fuel tank into position.
  15. Install the fuel tank straps.
  16. Install the fuel tank strap bolts. Tighten Tighten the bolts to 40 N.m (30 lb ft).
  17. Remove the adjustable jack from under the fuel tank.
  18. Remove the caps from the fuel and EVAP lines.
  19. Connect the fuel tank EVAP line quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  20. Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  21. Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
  22. Install the fuel tank shield bolts, if equipped. Tighten Tighten the bolts to 18 N.m (13 lb ft).
  23. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Extended Cab w//26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  24. Refill the fuel tank.
  25. Install the fuel cap.
  26. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  27. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-draining) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Remove the fuel tank shield bolts, if equipped.
  5. Remove the fuel tank shield from the fuel tank shield tabs (1), if equipped.
  6. Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember.
  7. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid.
  10. Remove the chassis wiring harness clip from the fuel tank shield.
  11. Disengage the retainer (1) securing the EVAP canister vent solenoid.
  12. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle.
  13. Disconnect the fuel tank fuel feed line quick connect fitting (1) from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Disconnect the fuel tank EVAP line quick connect fitting (2) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  15. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  16. Place a suitable adjustable jack under the fuel tank.
  17. Remove the fuel tank strap bolts.
  18. Remove the fuel tank straps.
  19. Lower the fuel tank half way.
  20. Disconnect the chassis wiring harness clip at the frame crossmember.
  21. Lower the fuel tank until the electrical connections are accessible.
  22. Disconnect the chassis wiring harness electrical connector (1) from the fuel tank pressure sensor.
  23. Disconnect the chassis wiring harness electrical connector (2) from the fuel tank module.
  24. Completely lower the fuel tank.
  25. With the aid of an assistant, place the fuel tank in a suitable work area.
  26. If replacing the fuel tank proceed to the next step, otherwise proceed to step 9 in the installation procedure.
  27. Remove the fuel tank shield push on retainers.
  28. Remove the fuel tank shield.
  29. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  30. Remove the fuel feed pipe from the fuel tank clips (1).
  31. Remove the EVAP pipe from the fuel tank clips (1).
  32. Disconnect the EVAP pipe quick connect fittings from the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  33. Remove the EVAP pipe from the fuel tank clips (1).
  34. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  1. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Position and connect the EVAP pipe quick connect fittings to the rollover valve and the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Install the EVAP pipe to the fuel tank clips (1).
  4. Install the EVAP pipe to the fuel tank clips (1).
  5. Position and connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  6. Install the fuel feed pipe to the fuel tank clips (1).
  7. Position and install the fuel tank shield.
  8. Install the fuel tank shield push on retainers.
  9. With the aid of an assistant, place the fuel tank in a the adjustable jack.
  10. Raise the fuel tank until the electrical connections can be made.
  11. Connect the chassis wiring harness electrical connector (2) to the fuel tank module.
  12. Connect the chassis wiring harness electrical connector (1) from the fuel pressure sensor.
  13. Completely raise the fuel tank into position.
  14. Install the fuel tank straps.
  15. Install the fuel tank strap bolts. Tighten Tighten the bolts to 40 N.m (30 lb ft).
  16. Remove the adjustable jack from under the fuel tank.
  17. Remove the caps from the fuel and EVAP lines.
  18. Connect the fuel tank EVAP line quick connect fitting (2) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  19. Connect the fuel tank fuel feed line quick connect fitting (1) to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  20. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle.
  21. Ensure that the retainer (1) is engaged, securing the EVAP canister vent solenoid.
  22. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  23. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  24. Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember.
  25. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid.
  26. Install the chassis wiring harness clip to the fuel tank shield.
  27. Position and install the fuel tank shield onto the fuel tank shield tabs (1), if equipped.
  28. Install the fuel tank shield bolts, if equipped. Tighten Tighten the bolts to 18 N.m (13 lb ft).
  29. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  30. Refill the fuel tank.
  31. Install the fuel cap.
  32. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  33. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion.
  1. Install the fuel tank pressure sensor.
  2. Install the fuel tank pressure sensor cover.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion.
  1. Install the fuel tank pressure sensor.
  2. Install the fuel tank pressure sensor cover.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion.
  1. Install the fuel tank pressure sensor.
  2. Install the fuel tank pressure sensor cover.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Remove the fuel tank module.
  2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover.
  3. Remove the fuel level sensor wiring pigtail from under the module clip (1).
  4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir.
  5. Slide the fuel level sensor up, in order to remove the sensor from the module slot.
  1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot.
  2. Ensure that the fuel level sensor retainers (2) engage the module reservoir.
  3. Install the fuel level sensor wiring pigtail under the module clip (1).
  4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover.
  5. Install the fuel tank module.
  1. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover.
  3. Remove the fuel level sensor wiring pigtail from under the module clip (2).
  4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir.
  5. Slide the fuel level sensor up, in order to remove the sensor from the module slot.
  1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot.
  2. Ensure that the fuel level sensor retainers (1) engage the module reservoir.
  3. Install the fuel level sensor wiring pigtail under the module clip (2).
  4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover.
  5. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  1. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover.
  3. Remove the fuel level sensor wiring pigtail from under the module clip (2).
  4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir.
  5. Slide the fuel level sensor up, in order to remove the sensor from the module slot.
  1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot.
  2. Ensure that the fuel level sensor retainers (1) engage the module reservoir.
  3. Install the fuel level sensor wiring pigtail under the module clip (2).
  4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover.
  5. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .

Fuel Tank Fuel Pump Module Replacement (Regular Cab with 20 Gal Tank)

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

  1. Remove the fuel tank.
  2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Reposition the fuel and EVAP pipes out of the way.
  5. Install the J 45722 fuel sender lock ring wrench (1) to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench.
  8. Remove the fuel tank module lock ring.
  9. Slowly raise the module until the fuel level sensor float arm is just visible.
  10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.
  12. Remove and discard the fuel tank module O-ring seal.
  13. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
  14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
  1. Install a NEW fuel tank module O-ring seal onto the fuel tank.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Lower the module assembly into the tank.
  4. Position and install the fuel tank module lock ring.
  5. Install the J 45722 fuel sender lock ring wrench to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench (1) from the fuel tank module lock ring.
  8. Position the fuel and EVAP pipes to the module.
  9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Install the fuel tank.

Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Reposition the fuel and EVAP pipes out of the way.
  5. Install the J 45722 fuel sender lock ring wrench (1) to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench.
  8. Remove the fuel tank module lock ring.
  9. Slowly raise the module until the fuel level sensor float arm is just visible.
  10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.
  12. Remove and discard the fuel tank module O-ring seal.
  13. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
  14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
  1. Install a NEW fuel tank module O-ring seal onto the fuel tank.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Lower the module assembly into the tank.
  4. Position and install the fuel tank module lock ring.
  5. Install the J 45722 fuel sender lock ring wrench to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench (1) from the fuel tank module lock ring.
  8. Position the fuel and EVAP pipes to the module.
  9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Install the fuel tank. Refer to «Fuel Tank Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .

Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Reposition the fuel and EVAP pipes out of the way.
  5. Install the J 45722 fuel sender lock ring wrench (1) to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench.
  8. Remove the fuel tank module lock ring.
  9. Slowly raise the module until the fuel level sensor float arm is just visible.
  10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.
  12. Remove and discard the fuel tank module O-ring seal.
  13. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
  14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
  15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.
  1. Install a NEW fuel tank module O-ring seal onto the fuel tank.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Lower the module assembly into the tank.
  4. Position and install the fuel tank module lock ring.
  5. Install the J 45722 fuel sender lock ring wrench to the fuel tank module lock ring.
  6. Using the J 45722 fuel sender lock ring wrench and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.
  7. Remove the J 45722 fuel sender lock ring wrench (1) from the fuel tank module lock ring.
  8. Position the fuel and EVAP pipes to the module.
  9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Install the fuel tank. Refer to «Fuel Tank Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.
  10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Position the fuel tank fill pipe.
  3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten Tighten the clamp to 2.5 N.m (22 lb in).
  4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Close the axle vent hose clip.
  7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  9. Install the fuel tank fill pipe ground wire bolt (3). Tighten Tighten the bolt to 9 N.m (80 lb in).
  10. Lower the vehicle.
  11. Install the fuel tank filler housing.
  12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the screws to 2.3 N.m (20 lb in).
  13. Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in).
  1. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe screws.
  3. Remove the fuel tank filler housing.
  4. Partially raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  5. Remove the fuel tank fill pipe ground wire bolt (3).
  6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and the chassis harness ground wire (1), if equipped.
  8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
  9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  10. Disconnect the vent tube attached at upper filler neck.
  11. Remove the fuel tank fill pipe.
  12. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.
  3. Connect the vent tube to the upper filler neck.
  4. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) . CAUTION: Refer to «Fastener Caution»(/gmc/sierra-2500/2012-2012/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
  5. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Tighten Tighten the clamp to 2.5 N.m (22 lb in).
  6. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
  7. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
  8. Install the fuel tank fill pipe ground wire bolt (3). Tighten Tighten the bolt to 9 N.m (80 lb in).
  9. Lower the vehicle.
  10. Install the fuel tank filler housing.
  11. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the bolts to 2.3 N.m (20 lb in).
  12. 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).
  1. Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  5. Remove the fuel tank fill pipe ground wire bolt.
  6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire.
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.
  10. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Position the fuel tank fill pipe.
  3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten Tighten the clamp to 2.5 N.m (22 lb in).
  4. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Close the axle vent hose clip.
  7. Position the fuel tank fill pipe ground wire to the frame bracket.
  8. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole.
  9. Install the fuel tank fill pipe ground wire bolt. Tighten Tighten the bolt to 9 N.m (80 lb in).
  10. Lower the vehicle.
  11. Install the fuel tank filler housing.
  12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten Tighten the screws to 2.3 N.m (20 lb in).
  13. Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten Tighten the screws to 2.3 N.m (20 lb in).
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the chassis fuel feed pipe (1) from the engine compartment feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Cap the fuel pipes in order to prevent possible fuel system contamination.
  4. Remove the fuel pipe retainer nuts (1).
  5. Remove the fuel pipe bracket bolt (2).
  6. Remove the fuel pipe retainer.
  7. Pull straight up on the pipe in order to remove the pipe from the fuel meter body.
  8. Remove and discard the following components from the fuel meter body: Fuel seal retainer (1) Upper fuel seal (2) Spacer ring (3) Lower fuel seal (4)
  1. Install the following NEW components to the fuel meter body: Lower fuel seal (4) Spacer ring (3) Upper fuel seal (2) Fuel seal retainer (1)
  2. Apply a few drops of clean engine oil to the fuel pipe end.
  3. Install the fuel pipe to the fuel meter body.
  4. Install the fuel pipe retainer.
  5. Install the fuel pipe bracket bolt (2). Tighten Tighten the bolt to 6 N.m (53 lb in).
  6. Install the fuel pipe retainer nuts (1). Tighten Tighten the nuts to 3 N.m (27 lb in).
  7. Remove the caps from the fuel pipes.
  8. Connect the chassis fuel feed pipe (1) to the engine compartment feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Test the system for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. Unclip the oxygen sensor harness connector from the bracket.
  10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  16. Unclip the inline harness connector from the bracket.
  17. Remove the fuel line bracket bolt (1).
  18. Remove the fuel/EVAP line clip nut (2).
  19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines.
  20. Unclip the line assembly from the frame.
  21. Remove the fuel/EVAP line clips from the frame and crossmember.
  22. Remove the fuel/EVAP line assembly from the vehicle.
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Clip the line assembly to the frame.
  3. Tighten the BPMV bolts.
  4. Install the fuel/EVAP line bracket locator tab to the frame.
  5. Install the fuel/EVAP line clips to the frame and crossmember.
  6. Clip the inline electrical connector to the bracket.
  7. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  8. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line.
  14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  15. Install the fuel line clip (1) to the bracket on the automatic transmission.
  16. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  17. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  18. Lower the vehicle.
  19. Remove the caps from the fuel rail and EVAP line.
  20. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  21. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line.
  12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  15. Remove the fuel line bracket bolt (1).
  16. Remove the fuel/EVAP line clip nut (2).
  17. Remove the fuel/EVAP line clips from the frame and crossmember.
  18. Remove the fuel/EVAP line assembly from the vehicle.
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  5. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  6. Remove the caps from the fuel and EVAP lines.
  7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line.
  11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  12. Install the fuel line clip (1) to the bracket on the automatic transmission.
  13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  14. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  15. Lower the vehicle.
  16. Remove the caps from the fuel rail and EVAP line.
  17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  19. Install the fuel fill cap.
  20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  21. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  15. Remove the fuel line bracket bolt (2).
  16. Remove the fuel/EVAP line clip nut (1).
  17. Remove the fuel/EVAP line clips from the frame and crossmember.
  18. Remove the fuel/EVAP line assembly from the vehicle.
  19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  22. Remove the fuel line bracket bolt (1).
  23. Remove the fuel/EVAP line clip nut (2).
  24. Remove the fuel/EVAP line clips from the frame and crossmember.
  25. Remove the fuel/EVAP line assembly from the vehicle.
  1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  5. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  6. Remove the caps from the fuel and EVAP lines.
  7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  10. Install the fuel/EVAP line bracket locator tab to the frame.
  11. Install the fuel/EVAP line clips to the frame and crossmember.
  12. Install the fuel/EVAP line bracket bolt (2). Tighten Tighten the bolt to 9 N.m (80 lb in).
  13. Install the fuel/EVAP line clip nut (1). Tighten Tighten the nut to 20 N.m (15 lb ft).
  14. Remove the caps from the fuel and EVAP lines.
  15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  20. Install the fuel line clip (1) to the bracket on the automatic transmission.
  21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  22. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  23. Lower the vehicle.
  24. Remove the caps from the fuel rail and EVAP line.
  25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  27. Install the fuel fill cap.
  28. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  29. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Fuel System Cleaning

  1. Remove the sending unit. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) , «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 20 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) , «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  2. Inspect the fuel strainer. Replace a contaminated strainer and inspect the fuel pump.
  3. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
  4. Flush the fuel tank with hot water.
  5. Pour the water out of the fuel sender assembly opening.
  6. Rock the tank to be sure that removal of the water from the tank is complete.
  7. Install the sending unit. Refer to «Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) , «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 20 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) , «Fuel Tank Fuel Pump Module Replacement (Regular Cab with 34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
  1. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/gmc/sierra-2500/2012-2012/remont/mechanical/#engine-mechanical-43l) .
  2. Reposition both sides of the fuel meter body bracket (1) until the tabs disengage from the fuel meter body, and lift the fuel meter body up.
  3. Remove and discard the fuel meter body seal.
  4. Prior to removal, clean the fuel meter body with a spray type engine cleaner, such as GM X-30A, or equivalent, if necessary. Follow the package instructions. Do not soak the fuel meter body in liquid cleaning solvent.
  5. Lightly pull on the fuel injector tube, and using a small pocket screwdriver, remove the fuel injector from the lower intake manifold bore.
  6. Remove the other 5 fuel injectors from the lower intake manifold bores.
  7. Remove the fuel meter body from the vehicle.
  1. Position the fuel tubes of the fuel meter body in the forward position.
  2. Install the fuel meter body into the fuel meter body bracket on the lower intake manifold.
  3. Install the 6 injectors into the proper lower intake manifold bores in proper sequence (5, 1, 3, 2, 4, 6).
  4. Inspect the injectors in order to ensure that they are firmly seated and locked in the lower intake manifold bores.
  5. Ensure that the electrical connections of the injectors are positioned so that they do not interfere with each other, and are pointing towards the center of the intake manifold. Rotate the electrical connections inboard if necessary. Also, ensure there is no tension on the injector wires.
  6. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/gmc/sierra-2500/2012-2012/remont/mechanical/#engine-mechanical-43l) .
  7. Tighten the fuel fill cap.
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  9. Test for fuel leaks using the following procedure: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  2. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/gmc/sierra-2500/2012-2012/remont/mechanical/#engine-mechanical-43l) .
  3. Remove the fuel pressure dampener retaining clip (7).
  4. Twist and pull the fuel pressure dampener (6) in order to remove the regulator from the housing using a shop towel to catch any spilled fuel.
  5. Remove and discard the dampener O-ring seal (5).
  6. Cover the fuel pressure dampener housing to prevent contamination from entering the fuel system.
  1. Lubricate the NEW O-ring with clean engine oil.
  2. Install the fuel pressure dampener O-ring seal (5).
  3. Install the fuel pressure dampener (6).
  4. Install the fuel pressure dampener retaining clip (7).
  5. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/gmc/sierra-2500/2012-2012/remont/mechanical/#engine-mechanical-43l) .
  6. Tighten the fuel fill cap.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  8. Inspect for leaks. Turn the ignition ON, for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON. Inspect for fuel leaks.

Fuel Injector Cleaning

Special Tools

  1. J 38500-A Fuel Injector Cleaner
  2. J 39021 Fuel Injector Coil and Balance Tester
  3. J 39021-210 Injector Tester Adapter Box
  4. J 39021-301 V6 Fuel Injector Test Adapter
  5. J 41413 EVAP Pressure and Purge Station
  6. J 44466-10 Regulator and Hose Assembly
  7. J 44466-11 IAFM Fuel Transfer Tube Recycling Block
  8. J 44466-12 CSFI Fuel Metering Body Jumper Block
  9. J 44466-13 Screws
  1. Loosen the fuel fill cap to relieve vapor pressure in the fuel tank.
  2. Relieve the fuel system pressure.
  3. Remove the positive crankcase ventilation (PCV) clean air tube from air inlet duct and set aside.
  4. Remove the resonator and air inlet duct from throttle body.
  5. Remove the brake booster vacuum hose and connector from intake manifold.
  6. Remove the electrical connector from the central sequential fuel injection (CSFI) fuel metering body.
  7. Remove the spark plug wires from 1, 3 and 5 from the distributor cap.
  8. Remove the fuel feed pipe bracket stud (3).
  9. Remove the fuel pipe retainer nuts (2) and retainer (1).
  10. Remove fuel feed pipe (4).
  11. Install the J 44466-12 CSFI fuel metering body jumper block (2) and the J 44466-13 screws (1) to the metering body and tighten.
  12. Install the J 44466-11 IAFM fuel transfer tube recycling block, retainer, and J 44466-13 screws to the fuel feed pipe and tighten.
  13. Obtain the J 41413 EVAP pressure and purge station, close the valve (2) on the tank (3), and remove the regulator assembly.
  14. Install the J 44466-10 regulator and hose assembly (5) to the J 41413 EVAP pressure and purge station tank (3)
  15. Connect the J 44466-10 regulator and hose assembly hose (1) to the J 44466-12 CSFI fuel metering body jumper block (3).
  16. Install the J 39021 fuel injector coil and balance tester, the J 39021-210 injector tester adapter box and J 39021-301 V6 fuel injector test adapter (4) to the metering body electrical connector.
  17. Adjust the amperage selector switch on J 39021 fuel injector coil and balance tester to 0.5 amps.
  18. Open the valve (2) on the tank (3).
  19. Open the valve (4) on the J 44466-10 regulator and hose assembly to pressurize the fuel system. Then close valve (4) before firing injectors. NOTE: The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank (3) must be refilled prior to performing this procedure.
  20. Fire one injector using the J 39021 fuel injector coil and balance tester. Observe a pressure drop on the gauge (6) and verify the injector/poppet valve operation. An injector/poppet that is stuck and not operational will have no pressure drop on the gauge. If an injector remains stuck, repeat the procedure multiple times (as required) until the injector is operational.
  21. Repeat steps 19 and 20 for each individual injector to verify that all injector/poppet valve assemblies are unstuck and functional.
  22. Shut off the pressure valve (2) on the tank (3) of the J 41413 EVAP pressure and purge station.
  23. Bleed off the pressure at the J 44466-10 regulator and hose assembly.
  24. Install the PCV fresh air tube to the air inlet duct.
  25. Disconnect and remove the J 44466-10 regulator and hose assembly (1) from the J 44466-12 CSFI fuel metering body jumper block (3) and the J 41413 EVAP pressure and purge station.
  26. Remove the J 39021-301 V6 fuel injector test adapter, J 39021-210 injector tester adapter box and J 39021 fuel injector coil and balance tester from the metering body.
  27. Install the vehicle electrical connector to the metering body.
  28. Install brake booster vacuum hose and connector to the intake manifold.
  29. Install ignition wires 1, 3, and 5 to the distributor cap.
  30. Install the resonator and air intake duct to the throttle body and hand tighten wing nut.
  31. Obtain J 38500-A fuel injector cleaner (2).
  32. Remove the canister top and add top engine cleaner GM P/N 1050002 (Canadian P/N 992872) to the canister.
  33. Fill the remainder of the canister with regular unleaded gasoline and install the canister top.
  34. Suspend J 38500-A fuel injector cleaner from a convenient underhood location.
  35. Connect the hose from J 38500-A fuel injector cleaner (1) to the service port on the J 44466-12 CSFI fuel metering body jumper block (3).
  36. Open valve (3) at the bottom of J 38500-A fuel injector cleaner.
  37. Connect a shop air source to the fitting at the top of J 38500-A fuel injector cleaner and adjust the regulator (1) to 75 psi.
  38. Let the vehicle run at idle until the canister is empty and the vehicle stalls.
  39. Remove the shop air supply from J 38500-A fuel injector cleaner.
  40. Depressurize the J 38500-A fuel injector cleaner.
  41. Disconnect the J 38500-A fuel injector cleaner hose from the J 44466-12 CSFI fuel metering body jumper block.
  42. Remove the PCV clean air tube from the air inlet duct and set aside.
  43. Remove the resonator and air inlet duct from the throttle body and set aside.
  44. Remove ignition wires 1, 3, and 5 from the distributor cap.
  45. Remove brake booster vacuum hose and connector from the intake manifold.
  46. Bleed the residual pressure from J 44466-12 CSFI fuel metering body jumper block.
  47. Remove J 44466-13 screws (1) and J 44466-12 CSFI fuel metering body jumper block (2) from the metering body.
  48. Remove J 44466-13 screws, retainer, and J 44466-11 IAFM fuel transfer tube recycling block from the fuel feed pipe.
  49. Install the fuel feed pipe (4) to the metering body.
  50. Install the retainer (1) and retainer nuts (2). Tighten Tighten the nuts to 3 (27 lb ft).
  51. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel feed pipe bracket stud (3).
  52. Install the fuel feed pipe bracket stud (3). Tighten Tighten the stud to 6 (53 lb ft).
  53. Install the brake booster vacuum hose and connector to the intake manifold.
  54. Install the resonator and air inlet duct to the throttle body.
  55. Install the PCV clean air tube to the inlet duct.
  56. Install brake booster vacuum hose and connector to the intake manifold.
  57. Install ignition wires 1, 3, and 5 to the distributor cap.
  58. Add 1 ounce of port fuel injector cleaner GM P/N 12345104 (Canadian P/N 12345515), or equivalent to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. NOTE: Instruct the customer to add the remainder of the bottle of port fuel injector cleaner to the vehicle fuel tank at the next fill up.
  59. Hand tighten the fuel tank filler cap.
  60. Start the vehicle and check for fuel leaks.
  61. Using a Tech II scan tool, check for any stored Powertrain DTC codes. Clear codes as required.
  62. Disconnect Tech II scan tool.
  1. Remove the fuel meter body. Refer to «Fuel Injector Fuel Meter Body Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Remove the injector retainer lock nuts (4) and retainer (3).
  3. While pulling the fuel injector downward, push with a small tip punch down between the injector terminals until the injector is removed.
  1. Lubricate the NEW injector O-ring seals with clean engine oil.
  2. Install the fuel injector (2) into the fuel meter body injector socket. CAUTION: Refer to «Fastener Caution»(/gmc/sierra-2500/2012-2012/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
  3. Install the injector retainer (3) and the injector retainer lock nuts (4). Tighten Tighten the nuts to 3 N.m (27 lb in).
  4. Install the fuel meter body. Refer to «Fuel Injector Fuel Meter Body Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the evaporative emission (EVAP) canister purge solenoid valve tube quick connect fitting (1) from the EVAP purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Reposition the tube out of the way.
  4. Disconnect the engine wiring harness electrical connector (1) from the EVAP purge valve solenoid.
  5. Remove the EVAP canister purge solenoid valve bolt (1).
  6. Remove the EVAP canister purge solenoid valve (2) from the upper intake manifold.
  7. Remove the EVAP canister purge solenoid valve O-ring seal (3) from the upper intake manifold, if necessary.
  1. Lubricate the EVAP canister purge solenoid valve O-ring seal with clean engine oil in order to aid with the installation.
  2. Install the EVAP canister purge solenoid valve (2) into the upper intake manifold.
  3. Install the EVAP canister purge solenoid valve bolt (1). Tighten Tighten the bolt to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the EVAP purge valve solenoid.
  5. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  6. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .

Note. Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.

  1. Lift and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2).
  3. Disconnect the vent solenoid hose retainers (1).
  4. Remove the vent solenoid hose and filter (2).
  5. Replace the vent hose with bulk 5/8 in heater hose.
  1. Use a hose clamp (1) at the end of the vent hose.
  2. Ensure the filter (3) points down.
  3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4).
  4. Secure the remaining portion of the vent hose along the frame with tie straps as needed.
  5. Position and install the evaporative canister vent solenoid (1) to the vehicle.
  6. Secure both ends with hose clamps (2).

Note. Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.

  1. Lift and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Cut the canister vent solenoid hose (1) approximately 76 mm (3 in) from the evaporative emission canister vent solenoid (2).
  3. Pull back on the retaining tab (1) and release the vent solenoid valve (2).
  4. Disconnect the vent solenoid hose from the plastic retainers (1).
  5. Remove the vent solenoid hose.
  6. Replace the vent hose with bulk 5/8 in heater hose.
  1. Use a hose clamp (1) at the end of the vent hose.
  2. Ensure the filter (3) points down.
  3. Secure the vent hose with a tie strap (2) to the vent hose tee connector (4).
  4. Use 5/8 in heater hose and secure it along the frame with tie straps as needed.
  5. Position and install the evaporative canister vent solenoid (1) to the vehicle.
  6. Use 5/8 in heater hose (2) to secure both ends with hose clamps (3).
IMPORTANTClean the evaporative emission (EVAP) line connection and surrounding areas before disconnecting in order to avoid possible EVAP system contamination.
  1. Disconnect the EVAP canister purge solenoid valve tube quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the EVAP canister purge solenoid valve tube quick connect fitting (1) from the EVAP canister purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Remove the EVAP canister purge solenoid valve tube.
  4. Cap the EVAP canister purge solenoid valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination.
  1. Remove the caps from the EVAP canister purge solenoid valve and the chassis EVAP pipe.
  2. Position the EVAP canister purge solenoid valve tube.
  3. Connect the EVAP canister purge solenoid valve tube quick connect fitting (1) to the EVAP canister purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Connect the EVAP canister purge solenoid valve tube quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. Unclip the oxygen sensor harness connector from the bracket.
  10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  16. Unclip the inline harness connector from the bracket.
  17. Remove the fuel line bracket bolt (1).
  18. Remove the fuel/EVAP line clip nut (2).
  19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines.
  20. Unclip the line assembly from the frame.
  21. Remove the fuel/EVAP line assembly from the vehicle.
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Clip the line assembly to the frame.
  3. Tighten the BPMV bolts.
  4. Install the fuel/EVAP line bracket locator tab to the frame.
  5. Install the fuel/EVAP line clips to the frame and crossmember.
  6. Clip the inline electrical connector to the bracket.
  7. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  8. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line.
  14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  15. Install the fuel line clip (1) to the bracket on the automatic transmission.
  16. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  17. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  18. Lower the vehicle.
  19. Remove the caps from the fuel rail and EVAP line.
  20. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  21. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  15. Remove the fuel line bracket bolt (2).
  16. Remove the fuel/EVAP line clip nut (1).
  17. Remove the fuel/EVAP line clips from the frame and crossmember.
  18. Remove the fuel/EVAP line assembly from the vehicle.
  19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  22. Remove the fuel line bracket bolt (1).
  23. Remove the fuel/EVAP line clip nut (2).
  24. Remove the fuel/EVAP line clips from the frame and crossmember.
  25. Remove the fuel/EVAP line assembly from the vehicle.
  1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  5. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  6. Remove the caps from the fuel and EVAP lines.
  7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  10. Install the fuel/EVAP line bracket locator tab to the frame.
  11. Install the fuel/EVAP line clips to the frame and crossmember.
  12. Install the fuel/EVAP line bracket bolt (2). Tighten Tighten the bolt to 9 N.m (80 lb in).
  13. Install the fuel/EVAP line clip nut (1). Tighten Tighten the nut to 20 N.m (15 lb ft).
  14. Remove the caps from the fuel and EVAP lines.
  15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.
  19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  20. Install the fuel line clip (1) to the bracket on the automatic transmission.
  21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  22. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  23. Lower the vehicle.
  24. Remove the caps from the fuel rail and EVAP line.
  25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  27. Install the fuel fill cap.
  28. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  29. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (Without CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-without-ch-48027) , «Fuel Pressure Relief (CH-48027)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions__fuel-pressure-relief-ch-48027) .
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  6. Unbolt and reposition the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  7. Remove the fuel pipe bracket nut from the bellhousing stud.
  8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line.
  12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  15. Remove the fuel line bracket bolt (1).
  16. Remove the fuel/EVAP line clip nut (2).
  17. Remove the fuel/EVAP line clips from the frame and crossmember.
  18. Remove the fuel/EVAP line assembly from the vehicle.
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Install the fuel/EVAP line bracket bolt (1). Tighten Tighten the bolt to 9 N.m (80 lb in).
  5. Install the fuel/EVAP line clip nut (2). Tighten Tighten the nut to 20 N.m (15 lb ft).
  6. Remove the caps from the fuel and EVAP lines.
  7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line.
  11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  12. Install the fuel line clip (1) to the bracket on the automatic transmission.
  13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten Tighten the nut to 25 N.m (18 lb ft).
  14. Position and install the front propeller shaft, if required. Refer to «Front Propeller Shaft Replacement»(/gmc/sierra-2500/2012-2012/remont/driveshaft-universal-joints/#propeller-shaft-and-universal-joints__front-propeller-shaft-replacement) .
  15. Lower the vehicle.
  16. Remove the caps from the fuel rail and EVAP line.
  17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  19. Install the fuel fill cap.
  20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (TP2)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) , «Battery Negative Cable Disconnection and Connection (Single Battery)»(/gmc/sierra-2500/2012-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  21. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Disconnect the fuel tank EVAP pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the chassis EVAP pipe quick connect fitting (2) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Remove the EVAP canister nut (1). (body shown removed, for clarity).
  6. Remove the EVAP canister assembly.
  7. If replacing the EVAP canister perform the following steps, otherwise proceed to step 3 in the installation procedure.
  8. Remove the EVAP canister bracket from the canister.
  1. If replacing the EVAP canister perform the following steps, otherwise proceed to step 3.
  2. Install the EVAP canister bracket to the canister.
  3. Install the EVAP canister assembly.
  4. Install the EVAP canister nut. Tighten Tighten the nut to 25 N.m (18 lb ft).
  5. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  6. Connect the chassis EVAP pipe quick connect fitting (2) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Connect the fuel tank EVAP pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Disconnect the EVAP canister pipe quick connect fitting (4) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Remove the EVAP canister nut. (body shown removed, for clarity).
  6. Remove the EVAP canister assembly.
  7. If replacing the EVAP canister perform the following steps, otherwise proceed to step 4 in the installation procedure.
  8. Remove the EVAP canister from the shield.
  9. Disconnect the EVAP canister pipes from the canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. If replacing the EVAP canister perform the following steps, otherwise proceed to step 4.
  2. Connect the EVAP canister pipes to the canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Install the EVAP canister to the shield.
  4. Install the EVAP canister assembly.
  5. Install the EVAP canister nut. Tighten Tighten the nut to 25 N.m (18 lb ft).
  6. Connect the EVAP canister pipe quick connect fitting (4) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. Disconnect the EVAP canister pipe quick connect fitting (2) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the EVAP canister vent solenoid pipe quick connect fitting (3) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Disconnect the EVAP canister pipe quick connect fitting (4) from the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  5. Remove the EVAP canister nut (1). (body shown removed, for clarity).
  6. Remove the EVAP canister assembly.
  7. If replacing the EVAP canister perform the following steps, otherwise proceed to step 4 in the installation procedure.
  8. Remove the EVAP canister bracket from the canister.
  9. Disconnect the EVAP canister pipe quick connect fittings from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  1. If replacing the EVAP canister perform the following steps, otherwise proceed to step 4.
  2. Install the EVAP canister bracket to the canister.
  3. Connect the EVAP canister pipe quick connect fittings to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  4. Install the EVAP canister assembly.
  5. Install the EVAP canister nut. Tighten Tighten the nut to 25 N.m (18 lb ft).
  6. Connect the EVAP canister pipe quick connect fitting (4) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  7. Connect the EVAP canister vent solenoid pipe quick connect fitting (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  8. Connect the EVAP canister pipe quick connect fitting (2) to the fuel tank EVAP pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  9. Lower the vehicle.

Evaporative Emission System Cleaning

Tools Required

J 41413-200 Evaporative Emissions System Tester (EEST)

Inspection Procedure

IMPORTANTDo not perform this procedure unless instructed by an evaporative emission (EVAP) diagnostic.
  1. Turn OFF the ignition.
  2. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Lightly tap the EVAP canister purge solenoid valve on a clean hard surface.
  4. Inspect for carbon particles exiting either of the vacuum ports. If no carbon particles are found reinstall the EVAP canister purge solenoid valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) . If carbon particles are found during the inspection procedure, replace the EVAP canister purge solenoid valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) . If you were instructed to replace the EVAP canister purge solenoid valve, and no carbon particles are found, return to the EVAP diagnostic procedure. Do not perform the EVAP cleaning procedure.

EVAP Cleaning Procedure

  1. Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) , «Evaporative Emission Canister Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) , «Evaporative Emission Canister Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Turn OFF the main valve on the J 41413-200 evaporative emissions system tester (EEST).
  3. Disconnect the hose from the diagnostic station pressure regulator.
  4. Using a section of vacuum hose, connect one end to the diagnostic station pressure regulator.
  5. Connect the other end of the vacuum hose to the canister side of the purge pipe.
  6. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
  7. If the nitrogen does not dislodge the carbon particles, replace the purge pipe.
  8. Return the EVAP pressure/purge diagnostic station to the stations original condition.
  9. Install a new EVAP canister. Refer to «Evaporative Emission Canister Replacement (Regular Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) , «Evaporative Emission Canister Replacement (Regular Cab w/34 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) , «Evaporative Emission Canister Replacement (Extended Cab w/26 Gal Tank)»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  10. Connect all previously disconnected EVAP pipe connectors.
  11. Lower the vehicle.
  12. Continue with the published service manual diagnostic DTC procedure.
  1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  2. Disconnect the chassis fuel feed pipe (1) quick connect fitting from the engine fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  3. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  4. Disconnect the engine wiring harness electrical connector (1) from the evaporative emission (EVAP) canister purge solenoid valve.
  5. Remove the engine wiring harness connector position assurance (CPA) retainer at the fuel meter body.
  6. Disconnect the engine wiring harness electrical connector (1) from the fuel meter body.
  7. Remove the engine wiring harness clips (1, 2) from the engine harness brackets.
  8. Remove the engine wiring harness rear bracket bolts and bracket.
  9. Disconnect the spark plug wires (1, 2) from the ignition coil.
  10. Reposition the spark plug wires out of the way.
  11. Disconnect engine wiring harness electrical connector (7) from the ignition coil.
  12. Reposition the engine wiring harness branches out of the way as required.
  13. Remove the ignition coil bolts and coil from the bracket.
  14. If required, remove the ignition coil bracket bolts and bracket.
  1. If required, position the ignition coil bracket to the lower intake manifold and install the bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
  2. Place the ignition coil on top of the bracket and install the bolts. Tighten Tighten the bolts to 12 N.m (106 lb in).
  3. Position the engine wiring harness branches as required.
  4. Connect engine wiring harness electrical connector (7) to the ignition coil.
  5. Position the spark plug wires to the ignition coil.
  6. Connect the spark plug wires (1, 2) to the ignition coil as noted during removal.
  7. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
  8. Install the engine wiring harness clips (1, 2) to the engine harness brackets.
  9. Connect the engine wiring harness electrical connector (1) to the fuel meter body.
  10. Install the engine wiring harness CPA retainer at the fuel meter body.
  11. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid valve.
  12. Connect the engine wiring harness electrical connector to the MAP sensor.
  13. Connect the chassis fuel feed pipe (1) quick connect fitting to the engine fuel feed pipe. Refer to «Metal Collar Quick Connect Fitting Service»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .
  14. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-repair-instructions) .

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions

  1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing.
  2. Any signs of cracks or splits in the wires.
  3. Inspect each boot for the following conditions: Tearing Piercing Arcing Corroded terminal

If corrosion, or arcing are indicated on a spark plug wire boot a terminal, replace the wire and inspect the components connected to the wire.

  1. Remove the appropriate spark plug wire boot(s) (1, 2) from the ignition coil. Twist the spark plug boot 1/2 turn. Pull ONLY on the spark plug boot or use a tool designed for this purpose, in order to remove the spark plug wire boot from the ignition coil.
  2. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). Twist the spark plug boot 1/2 turn. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug.
  3. Open the spark plug wire separators (1).
  4. Remove the appropriate spark plug wire(s).
  1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots.
  2. Install the appropriate spark plug wire(s)
  3. Close the spark plug wire separators (1).
  4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar).
  5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil.
  6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation. Push sideways on each boot in order to inspect the seating. Reinstall any loose boot. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot.

Spark Plug Inspection

  1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to the Electronic Parts Catalog.
  2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug
  3. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move.
  4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
  5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
  6. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-specifications__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/gmc/sierra-2500/2012-2012/remont/testing-diagnostics/#engine-controlsfuel-43l-specifications__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
  7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Visual Inspection

  1. Normal operation-Brown to grayish tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
  2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak ignition coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
  3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not affect spark intensity unless they form into a glazing over the electrode.
  1. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. Twist the spark plug boot 1/2 turn. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug.
  2. Loosen the spark plug 1 or 2 turns.
  3. Brush or air blast away any dirt from around the spark plug.
  4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number.
  1. Inspect the spark plug gap. Adjust the gap as needed. Refer to «Engine Mechanical Specifications»(/gmc/sierra-2500/2012-2012/remont/mechanical/#engine-mechanical-43l__engine-mechanical-specifications) .
  2. Install the spark plug into the cylinder head by hand.
  3. Tighten the spark plug to 15 N.m (11 lb ft).
  4. If reinstalling the old spark plug wires, apply dielectric grease GM P/N 12345579 (Canadian P/N 10953481), or equivalent to the inside the spark plug wire boots.
  5. Install the appropriate spark plug wire boot(s) (2) to the spark plug.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. If equipped, remove the oil pan skid plate and bolts.
  3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor.
  4. Remove the CKP sensor bolt and sensor.
  1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor.
  2. Lubricate the O-ring seal with clean engine oil.
  3. Install the CKP sensor and bolt. Tighten Tighten the bolt to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (4) to the CKP sensor.
  5. If equipped, position the oil pan skid plate and install the bolts. Tighten Tighten the bolts to 28 N.m (21 lb ft).
  6. Lower the vehicle.
  7. Perform the crankshaft position system variation learn procedure. Refer to «Control Module References»(/gmc/sierra-2500/2012-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
  1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper.
  2. Remove the water pump. Refer to «Water Pump Replacement (V6)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__water-pump-replacement-v6) .
  3. Remove the CMP sensor bolt.
  4. Remove the CMP sensor and wiring harness jumper from the engine front cover.
  5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor.
  6. Remove the CMP sensor from the wiring harness jumper.
  1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor.
  2. Install the CMP sensor to the wiring harness jumper.
  3. Connect the CMP sensor wiring harness jumper to the CMP sensor.
  4. Lubricate the O-ring seal with clean engine oil.
  5. Install the CMP sensor and wiring harness jumper to the engine front cover.
  6. Install the CMP sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in).
  7. Install the water pump. Refer to «Water Pump Replacement (V6)»(/gmc/sierra-2500/2012-2012/remont/cooling-system-mechanical/#engine-cooling-system__water-pump-replacement-v6) .
  8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. If equipped, remove the oil pan skid plate and bolts.
  3. Remove the knock sensor heat shield bolt and shield.
  4. Reposition the knock sensor sleeve (2) down, away from the knock sensor.
  5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor.
  6. Remove the knock sensor bolt and sensor.
  1. Position the knock sensor to the engine block and install the bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
  2. Connect the engine wiring harness electrical connector (1) to the knock sensor.
  3. Position the knock sensor sleeve (2) up and over the knock sensor.
  4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten Tighten the bolt to 10 N.m (89 lb in).
  5. If equipped, position the oil pan skid plate and install the bolts. Tighten Tighten the bolts to 28 N.m (21 lb ft).
  6. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/gmc/sierra-2500/2012-2012/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
  2. If equipped, remove the oil pan skid plate and bolts.
  3. Reposition the knock sensor sleeve (3) down, away from the knock sensor.
  4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor.
  5. Remove the knock sensor bolt and sensor.
  1. Position the knock sensor to the engine block and install the bolt. Tighten Tighten the bolt to 25 N.m (18 lb ft).
  2. Connect the engine wiring harness electrical connector (1) to the knock sensor.
  3. Position the knock sensor sleeve (3) up and over the knock sensor.
  4. If equipped, position the oil pan skid plate and install the bolts. Tighten Tighten the bolts to 28 N.m (21 lb ft).
  5. Lower the vehicle.

Scheme 128

Scheme 128: Air Cleaner Element Replacement
Scheme 128: Air Cleaner Element Replacement
CalloutComponent Name
1Air Cleaner Housing Cover Screw (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 3 N.m (27 lb in)
2Air Cleaner Housing
3Air Cleaner Element
CAUTION
Refer to Fastener Caution .

Air Cleaner Element Replacement

Scheme 129

Scheme 129: Air Cleaner Assembly Replacement
Scheme 129: Air Cleaner Assembly Replacement
CalloutComponent Name
Preliminary Procedures If replacing, remove the mass airflow sensor. Refer to Mass Airflow Sensor with Intake Air Temperature Sensor Replacement . Disconnect the air cleaner outlet duct from the air cleaner assembly. Refer to Air Cleaner Resonator Outlet Duct Replacement .
1Air Cleaner Assembly TIP: Pull upward in a jerking manner in order to disengage the air cleaner housing from the insulators.

Air Cleaner Assembly Replacement

  1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator.
  2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor.
  3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body.
  4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor.
  1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body.
  2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten Tighten the clamp to 4 N.m (35 lb in).
  3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten Tighten the clamp to 4 N.m (35 lb in).
  4. Connect the PCV hose (1) to the air cleaner outlet resonator.

See also:
• Control Module References
• Battery Negative Cable Disconnection and Connection (TP2)
• Diagnostic Trouble Code (DTC) List - Vehicle
• Cooling System Draining and Filling (Vac-N-Fill Gasoline)
• Cooling System Draining and Filling (Static Fill)
• Fastener Caution
• Heated Oxygen and Oxygen Sensor Caution
• Lifting and Jacking the Vehicle
• Knee Bolster Replacement (With RPO SLT)
• Gasoline/Gasoline Vapors Warning
• Electrical Center Identification Views
• Safety Glasses Warning
• Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Front Propeller Shaft Replacement
• Upper Intake Manifold Replacement
• Ignition System Specifications
• Engine Mechanical Specifications
• Water Pump Replacement (V6)
• Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
• Air Cleaner Outlet Resonator Replacement
• Fuel Pressure Relief (Without CH-48027)
• Fuel Pressure Relief (CH-48027)
• Fuel Tank Draining
• Fuel Tank Fuel Pump Module Replacement (Extended Cab with 26 Gal Tank)

More articles — Engine Performance