Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 135 (ENGINE CONTROLS - REMOVAL & INSTALLATION)FUEL SYSTEMSFUEL TANKINSTALLATION
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F
Fuel Tank: Installation
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation
WARNING: This page is about a different car, the 2003 Pontiac Grand Am and 2003 Oldsmobile Alero. However, it is still accessible from the selected car via links, so may be relevant.
- Install the fuel sender assembly to the fuel tank. See FUEL SENDER ASSEMBLY .
- With the aid of an assistant, raise the fuel tank to the vehicle.
- Install the fuel tank retaining straps. Tighten the strap bolts to specification. See TORQUE SPECIFICATIONS .
- Connect the wiring harness into the multiway rear body connector.
- Connect the EVAP vapor pipe to the EVAP canister.
- Connect the fuel filler hose to the fuel tank. Tighten the fuel filler hose clamp to specification. See TORQUE SPECIFICATIONS .
- Install the rubber exhaust hangers.
- Install the exhaust heat shield. Tighten the exhaust shield bolt/nuts to specification. See TORQUE SPECIFICATIONS .
- Connect the fuel return pipe and fuel filter quick-connect fittings.
- Lower the vehicle.
- Refill the fuel tank.
- Install the fuel filler cap.
- Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
- Inspect for leaks by using the following procedure.
- Turn ignition switch to RUN position, with the engine OFF for 2 seconds.
- Turn ignition switch to OFF position for 10 seconds.
- Turn ignition switch to RUN position, with the engine OFF.
- Check for fuel leaks.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.