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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 5 (ENGINE CONTROL SYSTEM - 4.3L - TROUBLESHOOTING & DIAGNOSIS)FUEL TANK LEAK TESTTEST DESCRIPTION
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Test Description

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Test Description
WARNING: This page is about a different variant/trim than selected.

The numbers below refer to the step numbers on the diagnostic table.

  1. 4:  This step tests for fuel leaks below the fuel tank fuel level.
  2. 5:  This step tests for fuel vapors escaping above the fuel level in the fuel tank.
Fuel Tank Leak Test

Step Action Yes No
1 Did you perform the Diagnostic System Check - Vehicle? Go to Step 2  Go to Diagnostic System Check - Vehicle
2
CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Inspect the fuel tank and fuel pipes for damage or external leaks.
Did you find fuel leaking from the fuel tank?		 Go to Step 6  Go to Step 3 
3
  1. Turn ON the ignition, with the engine OFF.
  2. Command the fuel pump relay ON with a scan tool.
  3. Inspect for fuel leaking from the fuel pipes.
Did fuel leak from the fuel pipes?		 Go to Step 7  Go to Step 4 
4 
  1. Turn OFF the ignition.
  2. Install the J 41413-200  Evaporative Emissions System Tester (EEST) and the J 41415-40  Fuel Tank Cap Adapter or the GE-41415-50  Interrupted Thread Fuel Tank Cap Adapter.
    3. IMPORTANT: If the floating indicator registers any flow after stabilizing, a leak is evident.
  3. Test for a fuel tank leak referring to the J 41413-210 Operation Manual.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Inspect for a fuel leak while the system is under pressure.
Did fuel leak from the fuel tank?		 Go to Step 6  Go to Step 5 
5 
  1. Using the J 41413-200  and the J 41413-210 Operation Manual, introduce smoke into the evaporative emission (EVAP) system. See Special Tools .
    2. IMPORTANT: It may be necessary to partially lower the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank) or Fuel Tank Replacement (Passenger/Cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) .
  2. Inspect for leaks in any of the following locations:
Did you find and correct the condition?		 Go to Step 8  Go to Diagnostic Aids
6 Replace the fuel tank. Refer to Fuel Tank Replacement (Cutaway Van Side Tank) or Fuel Tank Replacement (Passenger/Cargo Van) or Fuel Tank Replacement (Cutaway Van Rear Tank) .
Did you complete the repair?		 Go to Step 8  -
7 Replace the leaking fuel pipe. Refer to Fuel Hose/Pipes Assembly Replacement (Passenger/Cargo Van Fuel Tank Pipes) or Fuel Hose/Pipes Assembly Replacement (Cutaway Van Rear Tank Fuel Tank Pipe) .
Did you complete the replacement?		 Go to Step 8  -
8 Operate the system in order to verify the repair.
Did you correct the condition?		 System OK Go to Step 2 
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.