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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 136 (ENGINE CONTROLS - SYSTEM & COMPONENT TESTING)FUEL SYSTEMSFUEL TANK LEAK TESTDIAGNOSTIC PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Diagnostic Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Diagnostic Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Did you perform the Diagnostic System Check-Engine Controls? If yes, go to next step. If no, see DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS in SELF-DIAGNOSTICS - 5.7L CORVETTE article.
    2. NOTE: Before performing this procedure, place a dry chemical (class B) fire extinguisher near the work area.
  2. Raise the vehicle. Inspect the fuel tank and fuel pipes for damage or external leaks. Did you find fuel leaking from the fuel tank? If yes, go to step  6 . If no, go to next step.
  3. Turn ignition ON, with the engine OFF. With a scan tool, command fuel pump ON. Inspect for fuel leaking from fuel pipes. Did fuel leak from fuel pipes? If yes, go to step  7 . If no, go to next step.
  4. Install Fuel Tank Cap Adapter (J-41415-40). Connect EVAP Emission System Tester (J-41413-200) to fuel tank cap adapter. With a scan tool, seal the EVAP system. DO NOT exceed 15 in. H2O. With the EVAP Emission System Tester, pressurize the fuel tank. Did fuel leak from the fuel tank? If yes, go to step  6 . If no, go to next step.
  5. With EVAP Emission System Tester, maintain pressure in the fuel tank. The fuel tank may need to be partially lowered. With the Ultrasonic Leak Detector (J 41416), test for leaks above fuel level in the following locations.
    • The fuel tank, fill limiter vent valve, pressure relief valve and rollover valves.
    • The fuel sender housing and fuel sender seal.
    • The Fuel Tank Pressure (FTP) sensor seal.
    • The EVAP vapor pipes.
    • The fuel fill pipe and hose.

    Did you find and correct the condition? If yes, go to step  8 . If no, see DIAGNOSTIC AIDS  .

  6. Replace the fuel tank. After repair is complete, go to step  8 .
  7. Replace the leaking fuel pipe. After repair is complete, go to step  8 .
  8. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If no, go to Step  2 .
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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.