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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 Side Tank) >> Installation Procedure

Installation Procedure

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    Fig 1: View Of fuel tank straps
    GM1822370Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank insulators (6).
  2. Remove the caps from the fuel and EVAP pipes.
    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. Install the fuel sender assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement .
  5. Connect the EVAP pipe to the roll-over valves and the retainer clips.
    6. Fig 2: View Of fuel sender
    GM1823416Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connector to the fuel sender.
  9. Connect the fuel feed pipe and the fuel return pipe to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Raise the tank fully.
  11. Install the fuel tank straps (2).
    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 (1) to the fuel tank straps.

    Tighten:  Tighten the fuel tank strap attaching bolts to 20.5 N.m (15 lb ft).

  13. Connect the rear EVAP pipe (1) to the EVAP canister.
  14. Connect the fuel fill vent hose to the fill pipe.
    15. Fig 3: View Of fuel fill pipe
    GM1823384Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel fill hose to the fuel fill pipe.

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

  16. Lower the vehicle.
  17. Refill the fuel tank.
  18. Tighten the fuel filler cap.
  19. Connect the negative battery cable.
  20. 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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