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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) >> Removal Procedure

Removal Procedure

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    Fig 1: View Of fuel feed pipe
    GM1823384Courtesy 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. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
  6. Loosen the fuel fill hose clamp.
  7. Disconnect the fuel fill hose from the fuel fill pipe.
  8. Disconnect the fuel fill vent hose from the fill pipe.
  9. Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.
    10. Fig 2: View Of fuel tank straps
    GM1823416Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove the attaching bolts (1) from the fuel tank straps. Discard attaching bolts.
  12. Remove the fuel tank straps (2).
  13. Carefully lower the fuel tank.
  14. Disconnect the fuel feed pipe and the fuel return pipe at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
  15. Disconnect the electrical connector from the fuel sender.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
  18. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
  19. Remove the EVAP pipe from the roll over valves and the retainer clips.
  20. Remove the fuel sender assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  21. Remove the fuel fill hose from the fuel tank.
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