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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G3500, VAN CARGO, 4.8 VREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL SYSTEM CLEANING
2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 V

Fuel System Cleaning

2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 VSECTION Fuel System Cleaning
WARNING: This page is about a different variant/trim than selected.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
  2. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Drain fuel tank. Refer to Fuel Tank Draining Procedure .
  4. Remove 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) .
  5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
  6. Inspect the fuel strainer. Replace a contaminated strainer and inspect the fuel pump.
  7. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
    8. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all applicable local, state and federal laws and regulations.
  8. Flush the fuel tank with hot water.
  9. Pour the water out of the fuel sender assembly opening.
  10. Rock the tank to ensure that removal of the water from the tank is complete.
  11. Inspect the fuel filter for contamination.
  12. Replace the fuel filter if the filter is plugged. Refer to Fuel Filter Replacement (Passenger/Cargo Van)  or Fuel Filter Replacement (Cutaway Van) .
    13. IMPORTANT: Only use oil-free compressed air to blow out the fuel pipes.
  13. Clean the fuel lines by applying air pressure in the opposite direction of the fuel flow.
  14. Install the fuel sender assembly with a new seal into the fuel tank. Refer to Fuel Sender Assembly Replacement .
  15. Install 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) .
  16. 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.
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.