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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 (PICKUP)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: View Of Fuel Feed & Return Lines At Sending Unit
    GM1306338Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, install the sending unit. Refer to Fuel Sender Assembly Replacement .
  2. Install and connect the fuel feed (1) and return (2) lines to the sending unit and retaining clips. Refer to Metal Collar Quick Connect Fitting Service .
    3. Fig 2: Fuel Tank Assembly
    GM1228093Courtesy of GENERAL MOTORS CORP.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank until the sending unit electrical connection can be made.
  5. Connect the sending unit electrical connector.
  6. Install the fuel tank.
  7. Install the fuel tank straps.
    CAUTION: Refer to Fastener Caution .
  8. Install the fuel tank strap bolts.

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

  9. Remove the jack from under the fuel tank.
    10. Fig 3: View Of Fuel Feed & Return Lines At Fuel Tank
    GM1228124Courtesy of GENERAL MOTORS CORP.
  10. Remove the caps from the fuel lines.
  11. Connect the fuel feed and return lines to the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
    12. Fig 4: View Of Fuel Tank Shield & Bolts
    GM626413Courtesy of GENERAL MOTORS CORP.
  12. If necessary, install the fuel tank shield.
  13. If necessary, install the fuel tank shield bolts.

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

  14. Install the fuel system cooler. Refer to Fuel Cooler Replacement (Pickup)  or Fuel Cooler Replacement (Cab/Chassis) .
    15. Fig 5: Fuel Fill Pipe Assembly
    GM1378752Courtesy of GENERAL MOTORS CORP.
  15. Install the fuel tank fill pipe and vent hose to the fuel tank.
  16. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

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

  17. Tighten the fuel tank vent hose clamp (1) at the fuel tank.

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

    18. Fig 6: Fuel Tank Fill Pipe Ground Wire Bolt, Ground Wire & Chassis Harness Ground Wire
    GM1238144Courtesy of GENERAL MOTORS CORP.
  18. Position the fuel tank ground strap (3).
  19. Install the fuel tank ground strap bolt (1).

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

    20. Fig 7: Rear Axle Vent Hose On Fuel Fill Pipe
    GM1238161Courtesy of GENERAL MOTORS CORP.
  20. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  21. Lower the vehicle.
    22. Fig 8: Fuel Tank Filler Housing
    GM300318Courtesy of GENERAL MOTORS CORP.
  22. Install the fuel tank filler housing.
  23. Install the fuel tank filler housing to fuel tank fill pipe screws.

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

    24. Fig 9: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  24. Install the fuel tank filler housing to body screws (1), and retainer (2).

    Tighten:  Tighten the screws to 2.3 N.m (20 lb in).

  25. Fill the fuel tank.
  26. Install the fuel fill cap.
  27. 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) .
  28. Prime the fuel system. Refer to Fuel System Priming .
  29. Start the engine. If the engine stalls, repeat the above step.
  30. 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.