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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 927 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (PASSENGER/CARGO VAN)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 2007 GMC Savana and 2007 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of fuel tank
    GM1822370Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank into the fuel tank shield (3).
    2. NOTE: Refer to Fastener Notice .
  2. Install the fuel fill hose to the fuel tank.

    Tighten:  Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

  3. Place the EVAP canister in position on the EVAP canister bracket, then install two new tiedown straps.
  4. Install the EVAP hoses to the fuel tank and EVAP canister (2).
  5. Install the fuel sender assembly (1) and the fuel pipes to the fuel tank. Refer to Fuel Sender Assembly Replacement .
    6. Fig 2: View Of fuel tank
    GM1822211Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connectors to the fuel sender and fuel pump.
  9. Raise the tank fully.
  10. Install the fuel tank straps (2).
    11. IMPORTANT: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
  11. Install the new attaching bolts (4) to the fuel tank strap.

    Tighten:  Tighten the bolts to 20.5 N.m (15 lb ft).

    12. Fig 3: View Of chassis fuel feed pipe
    GM1822210Courtesy of GENERAL MOTORS CORP.
  12. Connect the chassis fuel feed pipe to the rear fuel feed pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
  13. Connect the rear fuel return pipe (1) to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    14. Fig 4: Identifying fuel fill hose
    GM1822209Courtesy of GENERAL MOTORS CORP.
  14. On passenger van, connect the fuel fill hose to the fuel tank.
    15. Fig 5: Identifying fuel fill hose
    GM1822206Courtesy of GENERAL MOTORS CORP.
  15. On cargo van, connect the fuel fill hose to the fuel tank.

    Tighten:  Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).

  16. On all models, lower the vehicle.
  17. Refill the fuel tank.
  18. Tighten the fuel filler cap.
  19. Connect the negative battery cable.
  20. Inspect for leaks:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect 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.