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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 52 (ENGINE CONTROLS - SYSTEM & COMPONENT TESTING - 8.1L)FUEL SYSTEMSFUEL TANK LEAK TESTDIAGNOSTIC PROCEDURES
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Diagnostic Procedures

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Diagnostic Procedures
WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 GMC Yukon XL, 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Suburban, and 2003 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Perform Diagnostic System Check - Engine Controls. See DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 8.1L AVALANCHE, SIERRA, SILVERADO, SUBURBAN & YUKON XL article.
    2. NOTE: Before performing this procedure, place a dry chemical (class "B") fire extinguisher near work area.
  2. Raise vehicle. Inspect fuel tank and fuel pipes for damage or external leaks. Did you find fuel leaking from fuel tank? If yes, go to step  6 . If no, go to next step.
  3. Turn ignition on, with engine off. Using scan tool, command fuel pump ON. Inspect for fuel leaking from fuel pipes. Did fuel leak from fuel pipes? If yes, go to step  7 . If no, go to next step.
  4. Turn ignition off. Install Fuel Tank Cap Adapter (J-41415-40). Connect Evaporative Emissions System Tester (J-41413-200) to fuel tank cap adapter. Turn ignition on, with engine off. Using scan tool, seal EVAP system. DO NOT exceed 15 in. H2O. With EVAP pressure/purge diagnostic station, pressurize fuel tank. Did fuel leak from fuel tank? If yes, go to step  6 . If no, go to next step.
    5. NOTE: Fuel tank may need to be partially lowered during this step.
  5. With EVAP pressure/purge diagnostic station, maintain pressure in fuel tank. With Ultrasonic Leak Detector (J-41416), test for leaks above fuel level in following locations:
    • Fuel tank, fill limiter vent valve, pressure relief valve and rollover valves.
    • Fuel sender housing and fuel sender seal.
    • Fuel Tank Pressure (FTP) sensor seal.
    • EVAP vapor pipes.
    • Fuel fill pipe and hose.

    Did you locate a fuel leak? If yes, go to next step. If no, see DIAGNOSTIC AIDS  .

  6. Replace fuel tank. After repairs, system is okay.
  7. Replace leaking fuel pipe. After repairs, system is okay.
  8. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If no, go to step  2 .
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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.