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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 (Passenger/Cargo) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of fuel fill hose
    GM1822370Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank into the fuel tank shield (3).
    2. NOTE: Refer to Fastener Notice .
  2. Install the fuel fill hose to the fuel tank.

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

  3. On models with EVAP canister mounted to fuel tank, place the (EVAP) canister in position on the (EVAP) canister bracket, then install two new tiedown straps.
  4. On all models, install the (EVAP) hoses to the fuel tank.
  5. Install the fuel sender assembly (1) and the fuel pipes to the fuel tank. Refer to Fuel Sender Assembly Replacement .
    6. Fig 2: View Of fuel tank straps
    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 connectors to the fuel sender and fuel pump.
  9. Raise the tank fully.
  10. Install the fuel tank straps (2).
    11. 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.
  11. Install the new attaching bolts (4) to the fuel tank strap.

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

    12. Fig 3: View Of fuel feed pipe
    GM1823384Courtesy of GENERAL MOTORS CORP.
  12. Connect the chassis fuel feed pipe to the rear fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel fill vent hose (2) to the filler tube.
  15. Connect the fuel fill hose (1) to the fuel tank.

    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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