2006 Chevrolet Suburban K1500, 5.3 ZFACTORY OEM SERVICE PROCEDURE

Fuel Tank Cleaning

IMPORTANT:
  • Only use oil free compressed air to blow out the fuel pipes.
  • Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Single Tank)  or Fuel Tank Draining Procedure (Dual Tanks - Front)  or Fuel Tank Draining Procedure (Dual Tanks - Rear)  or Fuel Tank Draining Procedure (5.3L (L59) Engine) .
  4. Remove the fuel tank. Refer to Fuel Tank Replacement (Single Tank)  or Fuel Tank Replacement (Dual Tanks - Front)  or Fuel Tank Replacement (Dual Tanks - Rear)  or Fuel Tank Replacement (Single Tank w/5.3L (L59) Engine) .
  5. Remove the fuel sender assembly. Refer to Fuel Sender Assembly Replacement (4.8L and 5.3L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Front)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Rear) .
  6. Inspect the fuel pump 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. Rock the tank to be sure that removal of the water from the tank is complete.
  10. Remove the fuel rail assembly. Refer to Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Rail Assembly Replacement (5.3L (L59) Engine) .
  11. Drain the fuel from the fuel rail. It will be necessary to remove the fuel injectors from the fuel rail to properly clear all debris from the fuel rail and fuel injectors. Use light shop air to remove any debris from the fuel rail and injectors.
  12. Replace the fuel injector O-rings.
  13. Use light shop air in the opposite direction of the fuel flow in order to remove any debris from the fuel lines. Catch any fuel from the fuel lines with an approved gasoline container.
  14. Install the injectors to the fuel rail.
  15. Install the fuel rail assembly onto the engine. Refer to Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)  or Fuel Rail Assembly Replacement (5.3L (L59) Engine) .
  16. If equipped with a serviceable fuel filter, replace the fuel filter.
  17. Install the fuel sender assembly. Refer to Fuel Sender Assembly Replacement (4.8L and 5.3L Engines)  or Fuel Sender Assembly Replacement (5.3L (L59) Engine)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Front)  or Fuel Sender Assembly Replacement (6.0L Engine - Dual Tanks - Rear) .
  18. Install the fuel tank. Refer to Fuel Tank Replacement (Single Tank)  or Fuel Tank Replacement (Dual Tanks - Front)  or Fuel Tank Replacement (Dual Tanks - Rear)  or Fuel Tank Replacement (Single Tank w/5.3L (L59) Engine) .
  19. Refill the fuel tank.
  20. Install the fuel filler cap.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
    22. IMPORTANT: If the fuel pump or sender assembly was not replaced, purge the fuel sender assembly.
  22. Purge the fuel sender assembly.
    1. Disconnect the fuel feed line from the fuel filter.
    2. Connect a length of hose to the fuel feed pipe.
    3. Insert the other end of the hose into an empty 3.8 liter (1 gallon) approved gasoline container.
    4. Add 23 liters (6 gallons) of clean fuel into the fuel tank.
    5. Turn on the fuel pump using the scan tool until 2 liters (1/2 gallon) of fuel flows into the fuel container.
  23. Inspect for leaks.
    1. Turn the ignition switch ON for 2 seconds.
    2. Turn the ignition switch OFF for 10 seconds.
    3. Turn the ignition switch ON.
    4. Inspect for fuel leaks.
Factory Service Tools

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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.

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