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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 116 (ENGINE CONTROLS AND FUEL - 2.2L (L61) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.
    Fig 1: Identifying Fuel Tank Fuel Pump Module Wiring Harness Electrical Connector
    GM1789400Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027)  or Fuel Pressure Relief (With CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
  4. Remove the body wiring harness electrical connector clip (1) from the underbody.
  5. Disconnect the body wiring harness electrical connector (2) from the fuel tank fuel pump module wiring harness electrical connector.
    6. Fig 2: Identifying ABS Wiring Harness Electrical Connectors
    GM1789401Courtesy of GENERAL MOTORS CORP.
  6. Remove the rear antilock brake system (ABS) wiring harness electrical connector (2) clip from the EVAP canister.
  7. Disconnect the body wiring harness electrical connector (1) from the rear ABS wiring harness electrical connector (2).
  8. Remove the rear ABS wiring harness clip from the EVAP canister.
    9. Fig 3: Identifying Fuel Tank & Chassis Fuel Feed Pipe
    GM1789402Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  11. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
    12. Fig 4: View Of Fuel Fill Pipe Hose & EVAP Emission Pipe
    GM1789403Courtesy of GENERAL MOTORS CORP.
  12. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  13. Separate the fuel fill pipe hose from the fuel tank.
  14. Disconnect the fuel tank EVAP emission canister vent pipe quick connect fitting (2) from the fuel tank fill EVAP emission pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 5: Identifying Muffler Insulators And Hangers
    GM1787811Courtesy of GENERAL MOTORS CORP.
  15. Place a jackstand under the muffler assembly.
  16. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers.
  17. Slowly lower the muffler assembly allowing it to rest on the jackstand. If this is not possible, remove the muffler assembly. Refer to Muffler Replacement (Sedan SS, Maxx SS) , Muffler Replacement (Sedan LS, LT, Maxx LT) or Muffler Replacement (Sedan LTZ, Maxx LTZ) .
    18. Fig 6: View Of Fuel Tank Strap Bolts
    GM1789404Courtesy of GENERAL MOTORS CORP.
  18. Have assistants support either side of the fuel tank.
  19. Remove fuel tank strap bolts and straps.
  20. Place a suitable adjustable jack under the fuel tank, and have the assistants rest the fuel tank on the adjustable jack.
  21. If applicable, in order to clear the muffler assembly, slowly lower the right side of the fuel tank.
  22. Once the tank is clear of the right frame rail, lower the fuel tank down and remove forward toward the right side of the vehicle.
  23. If replacing the fuel tank, proceed to the disassembly procedure, if not proceed to the Installation Procedure.
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.