LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Chevrolet >> 2004 >> 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) >> Installation Procedure
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Installation Procedure

    Fig 1: Identifying Fuel Tank Components
    GM601669Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank insulators (3).
  2. Install the fuel tank into the fuel tank shield.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  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 and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
  5. Connect the EVAP pipe at the front roll-over valve (5), the rear roll-over valve (2), the EVAP canister (4), and the retainer clips.
    6. Fig 2: View Of Fuel Tank (Passenger/Cargo Van)
    GM34270Courtesy 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 the fuel pressure sensor.
  9. Raise the tank fully.
  10. Install the fuel tank straps (3).
    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 At The Fuel Filter Inlet
    GM892640Courtesy of GENERAL MOTORS CORP.
  12. Remove the caps from the fuel and EVAP pipes.
  13. Connect the chassis EVAP purge pipe to the EVAP canister.
  14. Connect the chassis fuel feed pipe to the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  15. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
    16. Fig 4: View Of Fuel Fill Hose
    GM1198965Courtesy of GENERAL MOTORS CORP.
  16. 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).

  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Tighten the fuel filler cap.
  20. Connect the negative battery cable.
  21. 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.
scientia non olet · About LEMON Manuals