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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 TANK FUEL PUMP MODULE REPLACEMENT (25 EXT/CREW CAB WITH 26 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 Pump Module & Lock Ring
    GM1854513Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW fuel tank module O-ring seal onto the fuel tank.
    2. NOTE: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Lower the module assembly into the tank.
  4. Position and install the fuel tank module lock ring.
  5. Ensure that the module sealing surface is clean and free of contamination.
    6. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
  6. Install the J 45722  to the fuel tank module lock ring.
    7. NOTE: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  7. Using the J 45722  and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.
    8. Fig 3: Special Tool On Fuel Tank Module Lock Ring
    GM1854512Courtesy of GENERAL MOTORS CORP.
  8. Remove the J 45722  (1) from the fuel tank module lock ring.
  9. Position the fuel and EVAP pipes to the module.
  10. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Install the fuel tank. Refer to Fuel Tank Replacement (35 Reg/Ext/Crew Cab With 34 Gal Tank)  or Fuel Tank Replacement (15 Ext/Crew Cab With 26 Gal Tank)  or Fuel Tank Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk)  or Fuel Tank Replacement (15 Rec Cab With 26 Gal Tank)  or Fuel Tank Replacement (25 Ext/Crew Cab With 26 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.