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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 271 (FUEL SYSTEM)FUEL TANK REMOVAL/INSTALLATIONNOTES
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Fuel Tank Removal/Installation: Notes

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Notes
WARNING: This page is about a different car, the 2004 Mazda 3. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Repairing a fuel tank containing fuel is dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
  1. Park the vehicle on a level surface.
  2. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION .)
    WARNING:
    • A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before draining fuel, make sure to discharge static electricity by touching a vehicle.
  3. Drain the fuel from the fuel tank using the following procedure:
    1. Disconnect the quick release connector (in the engine compartment). (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION .)
    2. Attach a long hose to the disconnected fuel pipe and drain the fuel into a proper receptacle.
    3. Ground the following PCM terminals using a jumper wire.
      • With immobilizer system: 1AR
      • Without immobilizer system: 1AQ
      Fig 1: Identifying PCM Wiring Harness Side Connector Terminals
      G00973845Courtesy of MAZDA MOTORS CORP.
    4. Turn the ignition switch to the ON position to start the fuel pump.
      CAUTION:
      • The fuel pump may malfunction if it is operated without any fuel in the fuel tank (fuel pump idling). Constantly monitor the amount of fuel being discharged and immediately stop operation of the pump when essentially no fuel is being discharged.
    5. When essentially no fuel is being discharged from the hose, turn the ignition switch to the LOCK position.
    6. Disconnect the negative battery cable.
  4. Remove the rear seat cushion. (See REAR SEAT REMOVAL/INSTALLATION .)
  5. Remove the service hole cover.
  6. Disconnect the fuel pump unit connector.
  7. Remove the charcoal canister protector. (See CHARCOAL CANISTER REMOVAL/INSTALLATION .)
  8. Lower the main silencer so that the insulator can be removed. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  9. Remove the insulator.
  10. Remove the rear under cover (LH).
  11. Remove in the order indicated in the table. See Except for California emission regulation applicable model  and For California emission regulation applicable model .
  12. Install in the reverse order of removal.
  13. Inspect all parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION .)
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.