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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 (PICKUP)REMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal 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. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
    4. Fig 1: Rear Axle Vent Hose
    GM816707Courtesy of GENERAL MOTORS CORP.
  4. Loosen the clamp at the fuel inlet neck.
  5. Remove the fuel fill hose from the inlet neck.
  6. Remove the fuel system cooler. Refer to Fuel System Cooler Replacement (Pickup)  or Fuel System Cooler Replacement (Cab/Chassis) .
  7. Remove the fuel tank shield bolts, if equipped.
  8. Remove the fuel tank shield, if equipped.
    9. Fig 2: Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel feed and return pipes from the fuel tank pipes. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
    10. Fig 3: Fuel Feed And Return Pipes
    GM877717Courtesy of GENERAL MOTORS CORP.
  10. Cap the fuel pipes in order to prevent possible fuel system contamination.
  11. Place a suitable adjustable jack under the fuel tank.
  12. Remove the fuel tank strap bolts.
    NOTE: Refer to Fuel Tank Strap Fastener Notice in Cautions and Notices.
  13. Remove the fuel tank straps.
    14. Fig 4: Fuel Tank, Strap & Bolts (Pickup)
    GM300138Courtesy of GENERAL MOTORS CORP.
  14. Remove the fuel tank.
  15. Lower the fuel tank until the electrical connector is accessible.
  16. Disconnect the sending unit electrical connector.
  17. With the aid of an assistant, place the fuel tank in a suitable work area.
  18. If necessary, loosen the fuel inlet hose clamp at the tank.
  19. If necessary, remove the fuel inlet hose from the tank.
  20. Disconnect and remove the fuel feed and return pipes from the sending unit (1) and retaining clips (3). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    21. Fig 5: Fuel Tank, Sending Unit & Retaining Clips
    GM738174Courtesy of GENERAL MOTORS CORP.
  21. If replacing the fuel tank, remove the sending unit. Refer to Fuel Sender Assembly Replacement .
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.