LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Control System & Fuel System - 6.6L (LLY) - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure

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 .
  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. On models with the evaporative emission (EVAP) canister attached to the fuel tank, position the EVAP canister to the fuel tank, then install two new tie-down straps to the (EVAP) canister.
  5. Install the (EVAP) hoses to the fuel tank and (EVAP) canister.
  6. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
    7. Fig 2: View Of Fuel Tank (Passenger/Cargo Van)
    GM34270Courtesy of GENERAL MOTORS CORP.
  7. With the aid of an assistant, position and support the fuel tank.
  8. Raise the fuel tank slightly.
  9. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  10. Raise the tank fully.
  11. Install the fuel tank straps (3).
    12. 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.
  12. Install the new attaching bolts (4) to the fuel tank straps.

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

  13. Connect the rear fuel feed pipe to the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 3: Identifying Negative Battery Cable
    GM1824281Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel fill vent hose (2) to the fuel tank.
  16. Connect the fuel fill hose (1) to the fuel fill pipe.

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

  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Tighten the fuel filler cap.
  20. Connect the negative battery cable.
  21. 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.
scientia non olet · About LEMON Manuals