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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Control System & Fuel System - 4.3L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (Passenger/Cargo Van) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Identifying negative battery cable
    GM1822206Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to BATTERY DISCONNECT CAUTION .
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027)  or Fuel Pressure Relief (Without CH 48027) .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Loosen the fuel fill hose clamp.
  6. On cargo van, disconnect the fuel fill hose from the fuel tank.
    7. Fig 2: Identifying fuel fill hose
    GM1822209Courtesy of GENERAL MOTORS CORP.
  7. On passenger van, disconnect the fuel fill hose from the fuel tank.
    8. Fig 3: View Of rear fuel return pipe
    GM1822210Courtesy of GENERAL MOTORS CORP.
  8. On all models, clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  9. Disconnect the rear fuel return pipe (1) at the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the rear fuel feed pipe (2) at the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 4: View Of fuel tank
    GM1822211Courtesy of GENERAL MOTORS CORP.
  11. With the aid of an assistant, support the fuel tank.
  12. Remove and discard the attaching bolts (1) from the fuel tank strap.
  13. Remove the fuel tank straps (2).
  14. Carefully lower the fuel tank.
  15. Disconnect the fuel sender and the fuel pump electrical connectors.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
    18. Fig 5: Identifying fuel sender assembly
    GM1822370Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel sender assembly (1) and the fuel pipes from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  19. Remove the evaporative emission (EVAP) hoses from the fuel tank and EVAP canister (2).
  20. Remove two tiedown straps from the EVAP canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
  21. Remove the fuel fill hose from the fuel tank.
  22. Remove the fuel tank from the fuel tank shield (3).
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