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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 54 (ENGINE CONTROLS - REMOVAL & INSTALLATION)FUEL SYSTEMS (CNG)FUEL TANKREMOVAL
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Fuel Tank: Removal

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove spare tire cover. Remove jack and tool kit. Remove spare tire. Remove 4 tank cover bolts. Remove the CNG tank cover. See Figure.
  2. Relieve the system pressure. See FUEL SYSTEM PRESSURE RELEASE (CNG) .
  3. Disconnect the negative battery cable.
  4. Remove the tank vent boot cover nuts and cover. See Figure.
  5. Disconnect the 3 harness connectors.
  6. Loosen the fill valve boot clamp and peel back the boot. See Fig 1.
  7. Disconnect the fill line at the fill valve.
  8. Loosen the clamp at the tank vent boot and peel back the boot to expose the union.
  9. Disconnect the fill line at the union. See Figure.
  10. Disconnect the fill line at the HPL.
  11. Disconnect the HPL to HPR fuel line at the HPL.
  12. Disconnect the Pressure Relief Device (PRD) line at the HPL.
  13. Remove the trunk trim panel.
  14. Remove the cargo net, the cargo net knobs and the left wheelhouse carpet.
  15. Remove the fill line from the fill valve to the union.
  16. Lower the rear seat.
  17. Loosen the vent hose clamps at the tank valve boot and the HPR mounting ring.
  18. Pull up the boot and loosen the fuel line at the HPR.
  19. Remove the lines and the vent boot as an assembly.
  20. Remove the spare tire bracket. See Fig 2.
  21. Mark the tank in 2 places approximately 180 degrees apart for re-installation reference.
  22. Remove the tank strap nuts and the bolts. See Fig 3. Discard the nuts and the bolts.
  23. Remove the clevis and the bridge pins. See Fig 4.
  24. Remove the tank straps.
  25. Position the CNG Tank Remover (J 43133), or equivalent, into the tank strap bolt holes. See Fig 5.
  26. Loop the Tank Remover straps around the tank and secure the straps to the tool. See Fig 6.
  27. Pull back the Tank Remover to pull the tank free from the bracket.
  28. Pull back on the straps to roll the tank to the upper level of the CNG Tank Remover. See Fig 7.
  29. Use a lifting device and the CNG Tank Sling (J 45529) to remove the tank from the vehicle. See Fig 8.
  30. Remove the Tank Remover with tank from the vehicle.
Fig 1: Locating Fill Valve Boot Clamp
G00196203Courtesy of GENERAL MOTORS CORP.
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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.