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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1541 (ENGINE CONTROLS AND FUEL - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL LINE REPLACEMENT - CHASSIS (EXTENDED CAB)INSTALLATION 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 2009 GMC Sierra and 2009 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of EVAP Lines
    GM1855297Courtesy of GENERAL MOTORS CORP.
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the fuel/EVAP line bracket bolt (1).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  5. Install the fuel/EVAP line clip nut (2).

    Tighten:  Tighten the nut to 20 N.m (15 lb ft).

  6. Remove the caps from the fuel and EVAP lines.
  7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 2: View Of EVAP Canister Vent Solenoid Clip & EVAP Canister Vent Solenoid Pipe Clip
    GM1855664Courtesy of GENERAL MOTORS CORP.
  9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line.
    11. Fig 3: Identifying Fuel Hose/Pipe Clip At Bracket On Transfer Case
    GM1855293Courtesy of GENERAL MOTORS CORP.
  11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  12. Install the fuel line clip (1) to the bracket on the automatic transmission.
    13. Fig 4: View Of Fuel/Evaporative Emission Pipe & Bracket
    GM1701047Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel pipe bracket nut to the bellhousing stud.

    Tighten:  Tighten the nut to 25 N.m (18 lb ft).

  14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .
  15. Lower the vehicle.
    16. Fig 5: View Of Fuel Feed Pipe
    GM1876017Courtesy of GENERAL MOTORS CORP.
  16. Remove the caps from the fuel rail and EVAP line.
  17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  19. Install the fuel fill cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (With Single Battery) or Battery Negative Cable Disconnection and Connection (With Auxiliary Battery) or Battery Negative Cable Disconnection and Connection (With Dual Batteries) .
  21. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect 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.