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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) >> Removal Procedure

Removal Procedure

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    Fig 1: View Of fuel fill hose
    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 the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  6. Loosen the fuel fill hose clamp.
  7. Disconnect the fuel fill hose (1) from the filler tube.
  8. Disconnect the fuel fill vent hose (2) from the filler tube.
  9. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    11. Fig 2: View Of fuel tank straps
    GM1823416Courtesy of GENERAL MOTORS CORP.
  11. With the aid of an assistant, support the fuel tank.
  12. Remove and discard the attaching bolts (1) from the fuel tank strap.
  13. Remove the fuel tank straps (2).
  14. Carefully lower the fuel tank.
  15. Disconnect the fuel sender and the fuel pump electrical connectors.
  16. Remove the fuel tank.
  17. Place the fuel tank in a suitable work area.
    18. Fig 3: Identifying fuel sender assembly
    GM1822370Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel sender assembly (1) and the fuel pipes from the fuel tank. Refer to Fuel Sender Assembly Replacement .
  19. Remove the evaporative emission (EVAP) hoses from the fuel tank.
  20. On models with EVAP canister mounted to fuel tank, remove two tiedown straps from the (EVAP) canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
  21. On all models, remove the fuel fill hose from the fuel tank.
  22. Remove the fuel tank from the fuel tank shield (3).
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