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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 678 (ENGINE CONTROLS - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTREMOVAL 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 2006 GMC Sierra and 2006 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Remove the fuel tank fill pipe. Refer to Filler Tube Replacement .
  4. Remove the EVAP canister vent solenoid. Refer to Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement .
  5. Remove the fuel tank shield bolts, if equipped.
  6. Remove the fuel tank shield, if equipped.
    Fig 1: Removing Fuel Tank Shield
    GM626413Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed and EVAP lines. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    Fig 2: Fuel And EVAP Lines At The Fuel Tank
    GM1238591Courtesy of GENERAL MOTORS CORP.
  8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
    Fig 3: Removing Fuel Tank
    GM1228093Courtesy of GENERAL MOTORS CORP.
  12. Lower the fuel tank half way.

    When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.

  13. Disconnect the electrical harness clip at the frame crossmember.
  14. Lower the fuel tank until the electrical connections are accessible.
  15. Disconnect the fuel pressure sensor electrical connector (1).
    Fig 4: Disconnecting Fuel Pressure Sensor Electrical Connector
    GM1238148Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the fuel sending unit electrical connector (2), perform the following:
    1. Disengage the gray retainer.
    2. Push down the black clip.
    3. Disconnect the connector.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
    19. Fig 5: Identifying Fuel Feed, EVAP Purge & FLVV Lines
    GM1306291Courtesy of GENERAL MOTORS CORP.
  19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
  20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
  21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
  22. If necessary, 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.