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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 TANK REPLACEMENT (PASSENGER/CARGO VAN)INSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 V

Installation Procedure

2006 Chevrolet Chevy Express G3500, Van Cargo, 4.8 VSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying Fuel Tank Components
    GM601669Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank insulators (3).
  2. Install the fuel tank into the fuel tank shield.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel fill hose to the fuel tank.

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

  4. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
    5. Fig 2: View Of Fuel Tank (Passenger/Cargo Van)
    GM34270Courtesy of GENERAL MOTORS CORP.
  5. With the aid of an assistant, position and support the fuel tank.
  6. Raise the fuel tank slightly.
  7. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  8. Raise the tank fully.
  9. Install the fuel tank straps (3).
    10. 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.
  10. Install the new attaching bolts (4) to the fuel tank strap.

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

  11. Connect the chassis fuel feed pipe to the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  12. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    13. Fig 3: View Of Fuel Fill Hose
    GM1198965Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel fill hose to the fuel fill pipe.

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

  14. Lower the vehicle.
  15. Refill the fuel tank.
  16. Tighten the fuel filler cap.
  17. Connect the negative battery cable.
  18. 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.