SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - INTRODUCTION (2 OF 2)REPAIR INSTRUCTIONSFUEL SYSTEM CLEANINGCLEANING WATER FROM THE FUEL SYSTEM
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Cleaning Water from the Fuel System

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Cleaning Water from the Fuel System
  1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection .
  2. Remove the sending unit. Refer to Fuel Sender Assembly Replacement .
  3. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. If there is rust, replace the rusted components.
  4. Clean the inside of the fuel tank and the fuel sender with hot water.
  5. Use compressed air in order to dry the fuel tank and the fuel sender.
  6. Disconnect the ends of the following lines:
    • The fuel filter inlet line (both ends)
    • The transfer pump pressure line and suction line (if applicable)
    • The fuel filter outlet line (both ends)
    • The fuel filter drain
    • The fuel return line (both ends)
  7. Inspect each of the pipes and lines.
  8. Replace any rusted pipes.
  9. Clean the inside of the fuel filter housing.
  10. Dry the fuel filter housing with compressed air.
  11. Dry the inside of each line with low pressure air.
  12. Disconnect the crankshaft position (CKP) sensor. Refer to Crankshaft Position Sensor Replacement .
  13. Install a new fuel filter. Refer to Fuel Filter Replacement .
  14. Install the sending unit. Refer to Fuel Sender Assembly Replacement .
  15. Add clean diesel fuel to the primary tank until the tank is 1/4 full.
  16. Reconnect the following lines:
    • The fuel filter inlet line
    • The fuel filter outlet line
    • The transfer pump pressure and suction (both ends) lines
    • The fuel return line (tank end)
  17. Connect the batteries.
  18. Install a hose on the fuel return line near the glow plug relay, and insert other end into a 7.6 liters (2 gallon) metal container.
  19. Turn ignition on with the engine OFF. Allow the fuel pump to run until the cycle ends or until 3.8 liters (1 gallon) of fuel has passed into the container.
  20. Turn the ignition OFF.
  21. Connect the fuel return line.
  22. Clean any fuel spillage from the engine.
  23. Reconnect the CKP sensor.
  24. Start and run the engine.
  25. Stop the engine.
  26. Check for oil leaks.
  27. Fill the fuel tank and add a biocide, if needed.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.