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Home >> Chevrolet >> 2005 >> Chevy Express G2500, Van Cargo Extended, 4.3 X, 4L60E/M30 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 4.3L - Introduction >> Repair Instructions >> Fuel Tank Replacement (Passenger/Cargo Van) >> Removal Procedure

Removal Procedure

    Fig 1: View Of Fuel Fill Hose
    GM1198965Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Loosen the fuel fill hose clamp.
  6. Disconnect the fuel fill hose from the fuel tank.
    7. Fig 2: View Of Fuel Feed Pipe At The Fuel Filter Inlet
    GM892640Courtesy of GENERAL MOTORS CORP.
  7. 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.
  8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  9. Disconnect the chassis fuel feed pipe at the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Disconnect the chassis evaporative emission (EVAP) purge pipe at the EVAP canister.
  11. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
    12. Fig 3: View Of Fuel Tank (Passenger/Cargo Van)
    GM34270Courtesy of GENERAL MOTORS CORP.
  12. With the aid of an assistant, support the fuel tank.
  13. Remove the attaching bolts (4) from the fuel tank strap.
  14. Remove the fuel tank straps (3).
  15. Carefully lower the fuel tank.
  16. Disconnect the fuel sender and the fuel pressure sensor electrical connectors.
  17. Remove the fuel tank.
  18. Place the fuel tank in a suitable work area.
    19. Fig 4: Identifying Fuel Tank Components
    GM601669Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.
  20. Remove the fuel sender assembly and the fuel pipes (6) from the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
  21. Remove the fuel fill hose from the fuel tank.
  22. Remove the fuel tank from the fuel tank shield.
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