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Home >> Chevrolet >> 2007 >> Chevy Express G2500, Van Cargo, 6.6 6 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine Control System & Fuel System - 4.8L, 5.3L, And 6.0L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (Cutaway Van Rear Tank) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Fuel Tank Insulators
    GM588986Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank insulators.
  2. Install the fuel sender assembly and the rear fuel and EVAP pipes to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  3. Install the fuel fill hose and fuel fill vent hose to the fuel tank.
    4. Fig 2: View Of Fuel Tank (Cutaway Van Rear Tank)
    GM34272Courtesy of GENERAL MOTORS CORP.
  4. With the aid of an assistant, position and support the fuel tank.
  5. Raise the fuel tank slightly.
  6. Connect the electrical connectors to the fuel sender and the fuel pressure sensor.
  7. Raise the tank fully.
  8. Install the fuel tank straps (3).
    9. NOTE: Refer to FASTENER NOTICE .
    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.
  9. Install the new attaching bolts (4) to the fuel tank straps.

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

    10. Fig 3: Locating Fuel Pipe Connections
    GM420630Courtesy of GENERAL MOTORS CORP.
  10. Remove the caps from the fuel and EVAP pipes.
  11. Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .
    12. Fig 4: View Of fuel fill vent hose
    GM1824186Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel fill vent hose (2) to the full pipe.
  13. Connect the fuel fill hose to the fuel tank (1).

    Tighten:  Tighten the fuel fill hose clamp (2) 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.
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