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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 941 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL COOLER REPLACEMENTINSTALLATION 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 Special, 2007 GMC Savana Camper Special, 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: Identifying DFCM Brackets
    GM1662568Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel cooler to the chassis and crossover.
    2. NOTE: Refer to Fastener Notice .
  2. Install the fuel cooler bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

  3. Connect the fuel lines at the fuel cooler. Refer to Metal Collar Quick Connect Fitting Service .
  4. Lower the vehicle.
  5. Prime the fuel system. Refer to Fuel System Priming .
  6. Start the engine. If the engine stalls, repeat the above step.
  7. Once the engine starts, 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.