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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1984 (ENGINE CONTROLS AND FUEL - 3.5L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK FUEL PUMP MODULE REPLACEMENT - SECONDARYREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Tank Wiring Harness
    GM1884873Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Disconnect the fuel tank wiring harness electrical connector (2) from the secondary fuel tank fuel pump module.
  3. Remove the fuel tank wiring harness from the retaining clip (3).
  4. Reposition the fuel tank wiring harness (1) out of the way.
  5. Install the CH-48482  to the fuel tank fuel pump module lock ring.
  6. Using the CH-48482  and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank fuel pump module lock ring.
  7. Remove the CH-48482  .
    8. Fig 2: Fuel Tank Fuel Pump Module
    GM1884875Courtesy of GENERAL MOTORS CORP.
  8. Remove the fuel tank module lock ring (1).
  9. Slowly raise the fuel tank fuel pump module (2) until the fuel level sensor float arm and primary fuel tank fuel pump module suction port are just visible.
    10. Fig 3: Primary Fuel Tank Fuel Pump Module Suction Port Tabs
    GM1884876Courtesy of GENERAL MOTORS CORP.
  10. Squeeze in the primary fuel tank fuel pump module suction port tabs on either side of the port in order to disengage the primary fuel tank fuel pump module suction port from the secondary fuel tank fuel pump module.
    11. Fig 4: Primary Fuel Tank Fuel Pump Module Suction Port
    GM1884877Courtesy of GENERAL MOTORS CORP.
  11. Remove the primary fuel tank fuel pump module suction port (2) from the secondary fuel tank fuel pump module (1).
    12. Fig 5: Fuel Tank Module
    GM1884878Courtesy of GENERAL MOTORS CORP.
  12. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module (1) from the tank.
  13. Remove and discard the fuel tank module O-ring seal (2).
  14. If the secondary fuel tank fuel pump module is being replaced, remove the secondary fuel level sensor, if required. Refer to Secondary Fuel Level Sensor Replacement .
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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.