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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 483 (ENGINE CONTROLS - 6.0L - ALTERNATIVE FUELS (INTRODUCTION))REPAIR INSTRUCTIONSFILL VALVE REPLACEMENTREMOVAL 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 and 2004 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
    2. CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical in the C/K Pickup service manual.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the C/K Pickup service manual. Remove the truck body or side panel as required on ZW9 equipped vehicles in order to gain access to the fill valve.
    4. Fig 1: Identifying Fill Line and Fill Valve
    GM757005Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the fill line (3) at the fill valve (2).
    5. Fig 2: Identifying Mounting Plate Bolts
    GM762852Courtesy of GENERAL MOTORS CORP.
  5. Remove the bolts (4) from the mounting plate (2).
    6. Fig 3: Locating Fill Valve Mounting Nut
    GM762870Courtesy of GENERAL MOTORS CORP.
  6. Remove the fill valve mounting nut (3).
  7. Remove the fill valve (2) from the vehicle.
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.