Tools Required

J 45878 Combustible Gas Detector

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the C/K Pickup service manual.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the C/K Pickup service manual. Remove the truck body or side panel as required on ZW9 equipped vehicles in order to gain access to the fill valve.



4. Disconnect the fill line (3) at the fill valve (2).



5. Remove the bolts (4) from the mounting plate (2).



6. Remove the fill valve mounting nut (3).
7. Remove the fill valve (2) from the vehicle.

1. Install the fill valve (2) into the mounting plate (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the fill valve nut (3).

Tighten
Tighten the nut to 41 N·m (30 lb ft).




3. Install the mounting plate (2) to the fill housing with the attaching bolts (4).

Tighten
Tighten the bolts to 8 N·m (71 lb in).




4. Connect the fill line (3) to the fill valve (2) with a new O-ring face seal. Lubricate the O-ring with petroleum jelly.

Tighten
Tighten the fitting to 37 N·m (27 lb ft).

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

5. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical in the C/K Pickup service manual.
6. Start the vehicle and inspect for CNG fuel leaks at the serviced fitting using the J 45878 or an equivalent liquid leak detector.