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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1369 (ENGINE CONTROLS AND FUEL - 3.6L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL TANK FUEL PUMP MODULE REPLACEMENT - RIGHT SIDEINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
GM1994068Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Always replace the fuel tank module seal when installing the fuel tank module assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
  1. Install a NEW fuel tank module seal (4).
  2. Grasp the fuel transfer hose from inside the fuel tank.
  3. Partially install the primary fuel tank module (1) to the fuel tank.
  4. Connect the fuel transfer hose quick connect fitting (3) to the port on the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service 
  5. GM1994064Courtesy of GENERAL MOTORS CORP.

    Press the right fuel pump tank module downward, aligning the module to the encapsulated ring.

    IMPORTANT: Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  6. Position the cam lock ring (3) to the fuel tank.
    IMPORTANT: DO NOT use impact tools. Significant force will be required to install the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.
  7. Use the J45722  (2) and a long breaker-bar (1) to install the fuel tank module lock ring (3), by turning clockwise, until fully seated.
  8. GM1994056Courtesy of GENERAL MOTORS CORP.

    Connect the electrical connector (3) to the right fuel pump tank module and engage the connector interlock.

  9. Install the wire harness (1) to the retainer on the fuel tank.
  10. Connect the fuel feed hose quick connect fitting (4) to the primary fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service 
  11. Install the fuel feed hose (2) to the retainer on the fuel tank.
  12. Install the fuel tank. Refer to Fuel Tank Replacement .
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.