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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1797 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.8L, 5.3L, 6.0L, 6.2L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL LEVEL SENSOR REPLACEMENT (35 REG/EXT/CREW CAB WITH 34 GAL TANK)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 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Level Sensor
    GM1854936Courtesy of GENERAL MOTORS CORP.
  1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot.
    2. Fig 2: Fuel Level Sensor Wiring Pigtail, Module Clip & Retainers
    GM1854935Courtesy of GENERAL MOTORS CORP.
  2. Ensure that the fuel level sensor retainers (1) engage the module reservoir.
  3. Install the fuel level sensor wiring pigtail under the module clip (2) behind the fuel pump wires.
    4. Fig 3: Fuel Level Sensor Wiring Pigtail Electrical Connector
    GM1854934Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover.
  5. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement (25 Ext/Crew Cab With 26 Gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk)  or Fuel Tank Fuel Pump Module Replacement (15 Ext/Crew Cab With 26 Gal Tank)  or Fuel Tank Fuel Pump Module Replacement (15 Reg Cab With 26 Gal Tank)  or Fuel Tank Fuel Pump Module Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank) .
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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.