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HOMESERVICE MANUALSCHEVROLET2005CHEVY EXPRESS H1500, VAN PASSENGERREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 4.3L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL HOSE/PIPES ASSEMBLY REPLACEMENT (PASSENGER/CARGO VAN FUEL TANK PIPES)INSTALLATION PROCEDURE
2005 Chevrolet Chevy Express H1500, Van Passenger

Installation Procedure

2005 Chevrolet Chevy Express H1500, Van PassengerSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Fuel Tank Components
    GM601669Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel feed and return pipes (6) to the fuel sender (1), the fuel filter, and the retaining clips.
  2. Install the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank)  or Fuel Tank Replacement (Passenger/Cargo Van)  or Fuel Tank Replacement (Cutaway Van Rear Tank) .
  3. Lower the vehicle.
  4. Refill the fuel tank.
  5. Tighten the fuel filler cap.
  6. Connect the negative battery cable.
  7. Inspect for leaks:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
RENDER: 1.0x

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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.