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HOMESERVICE MANUALSCHEVROLET2005CHEVY EXPRESS H1500, VAN PASSENGERREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 4.3L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (CUTAWAY VAN SIDE TANK)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 tank insulators (6).
  2. Remove the caps from the fuel and EVAP pipes.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel fill hose to the fuel tank.

    Tighten:  Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

  4. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  5. Connect the EVAP pipe to the roll-over valves and the retainer clips.
    6. Fig 2: View Of Fuel Tank (Cutaway Van Side Tank)
    GM601673Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  9. Connect the fuel feed pipe and the fuel return pipe to the fuel sender. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Raise the tank fully.
  11. Install the fuel tank straps (2).
    12. IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
  12. Install the new attaching bolts (1) to the fuel tank strap.

    Tighten:  Tighten the fuel tank strap attaching bolts to 20.5 N.m (15 lb ft).

  13. Connect the rear EVAP pipe (1) to the EVAP canister.
    14. Fig 3: View Of Fuel Tank Fill Pipe
    GM1198967Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel fill hose to the fuel fill pipe.

    Tighten:  Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

  15. Lower the vehicle.
  16. Refill the fuel tank.
  17. Tighten the fuel filler cap.
  18. Connect the negative battery cable.
  19. 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.