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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 380 (ENGINE CONTROLS - 6.6L (LB7) (INTRODUCTION))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (CAB/CHASSIS - FRONT)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 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps (1).
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

    7. Fig 1: Fuel Tank, Strap & Bolts (Cab/Chassis - Front)
    GM667731Courtesy of GENERAL MOTORS CORP.
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

    10. Fig 2: Fuel Tank Shield & Bolts
    GM877744Courtesy of GENERAL MOTORS CORP.
  10. Lower the vehicle.
  11. Connect the fuel feed/return pipes at the fuel tank. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    12. Fig 3: Fuel Feed/Return Pipes At Fuel Tank
    GM877707Courtesy of GENERAL MOTORS CORP.
  12. Connect the sending unit electrical connector.
  13. Install the fuel fill pipe and vent hose to the tank.
    14. Fig 4: Fuel Fill Pipe And Vent Hose (Cab/Chassis - Front)
    GM877738Courtesy of GENERAL MOTORS CORP.
  14. Tighten the fuel fill and vent hose clamps at the fuel tank.

    Tighten:  Tighten the clamps to 2.5 N.m (22 lb in).

  15. Connect the fuel feed and pressure balance rear pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    16. Fig 5: Fuel Feed And Pressure Balance Rear Pipes
    GM877728Courtesy of GENERAL MOTORS CORP.
  16. Fill the fuel tank.
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  19. Prime the fuel system.
  20. Start the engine and test 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.