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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 381 (ENGINE CONTROLS - 6.6L (LLY) (INTRODUCTION))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (PICKUP)REMOVAL 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 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Tank Filler Housing To Body Screws & Retainer
    GM853731Courtesy of GENERAL MOTORS CORP.
  1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  2. Remove the fuel tank filler housing to body screws (1), and retainer (2).
    3. Fig 2: Identifying Fuel Filler Components
    GM300318Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel tank filler housing to fuel tank fill pipe screws.
  4. Remove the fuel tank filler housing.
    5. Fig 3: Rear Axle Vent Hose On The Fuel Fill Pipe
    GM1238161Courtesy of GENERAL MOTORS CORP.
  5. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.
  6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    7. Fig 4: Fuel Tank Ground Strap Bolt
    GM1238144Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel tank ground strap bolt (1).
  8. Reposition the fuel tank ground strap (3).
    9. Fig 5: Fuel Fill Pipe Assembly
    GM1378752Courtesy of GENERAL MOTORS CORP.
  9. Loosen the fill pipe vent hose clamp (1) at the fuel tank.
  10. Remove the fill pipe vent hose from the fuel tank.
  11. Remove the fill pipe.
  12. Remove the fuel system cooler. Refer to Fuel System Cooler Replacement (Pickup)  or Fuel System Cooler Replacement (Cab/Chassis) .
    13. Fig 6: Fuel Tank Shield Bolts (Pickup)
    GM626413Courtesy of GENERAL MOTORS CORP.
  13. If equipped, remove the fuel tank shield bolts.
  14. If equipped, remove the fuel tank shield.
    15. Fig 7: View Of Fuel Feed And Return Lines At Fuel Tank (Pickup)
    GM1228124Courtesy of GENERAL MOTORS CORP.
  15. Disconnect the fuel feed and return lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  16. Cap the fuel lines in order to prevent possible fuel system contamination.
  17. Place a suitable adjustable jack under the fuel tank.
    18. Fig 8: View Of Fuel Tank Straps (Pickup)
    GM1228093Courtesy of GENERAL MOTORS CORP.
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.