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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2072 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L (LMM) - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (CAB/CHASSIS - FRONT)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Tank, Strap & Bolts
    GM1228169Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Remove the caps from the fuel lines.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps.
    CAUTION: Refer to Fastener Caution .
  6. Install the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 40 N.m (30 lb ft).

  7. Remove the jack from under the fuel tank.
    8. Fig 2: Fuel Tank Shield & Bolts
    GM877744Courtesy of GENERAL MOTORS CORP.
  8. If necessary, install the fuel tank shield.
  9. If necessary, install the fuel tank shield bolts.

    Tighten:  Tighten the bolts to 18 N.m (13 lb ft).

  10. Lower the vehicle.
    11. Fig 3: Fuel Feed & EVAP Quick Connect Fittings At Sending Unit
    GM1228206Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel feed and return lines at the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
    12. Fig 4: Fuel Pressure Sensor Electrical Connector & Fuel Sending Unit Electrical Connector
    GM1238183Courtesy of GENERAL MOTORS CORP.
  12. Connect the sending unit electrical connectors (1).
    13. Fig 5: View Of Fuel Fill Pipe Clamp & Vent Pipe Clamp
    GM1228174Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel fill pipe and vent hose to the tank.
  14. Tighten the fuel fill and vent hose clamps (1, 2) at the fuel tank.

    Tighten:  Tighten the clamps to 2.5 N.m (22 lb in).

    15. Fig 6: View Of Fuel Feed & Pressure Balance Lines
    GM1228187Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel feed and pressure balance rear lines. Refer to Metal Collar Quick Connect Fitting Service .
  16. Fill the fuel tank.
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) or Battery Negative Cable Disconnection and Connection (Dual Batteries) or Battery Negative Cable Disconnection and Connection (Auxiliary Battery) .
  19. Prime the fuel system. Refer to Fuel System Priming .
  20. Start the engine. If the engine stalls, repeat the above step.
  21. Once the engine starts, inspect for fuel leaks.
RENDER: 1.0x

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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.