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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) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of fuel fill pipe
    GM1824186Courtesy 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. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to Lifting and Jacking the Vehicle .
  5. Disconnect the fuel fill hose (1) from the fuel fill tube.
  6. Disconnect the fuel fill vent hose (2) from the fuel fill tube.
    7. Fig 2: Locating Fuel Pipe Connections
    GM420630Courtesy of GENERAL MOTORS CORP.
  7. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  8. Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
    10. Fig 3: View Of Fuel Tank (Cutaway Van Rear Tank)
    GM34272Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove the attaching bolts (4) from the fuel tank straps. Discard attaching bolts.
  12. Remove the fuel tank straps (3) and two fuel tank strap insulators.
  13. Carefully lower the fuel tank.
  14. Disconnect the electrical connectors from the fuel sender and the fuel pressure sensor.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.
  17. Remove the fuel fill hose and fuel fill vent hose from the fuel tank.
  18. Remove the fuel sender assembly and the rear fuel and EVAP pipes from the fuel tank. Refer to Fuel Sender Assembly Replacement .
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