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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 143 (ENGINE CONTROLS AND FUEL - 3.5L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL PUMP MODULE REPLACEMENT (MAXX)REMOVAL 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.
    Fig 1: Identifying Fuel Pump Module Wiring Harness Connectors
    GM1796271Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel tank. Refer to Fuel Tank Replacement (Maxx)  or Fuel Tank Replacement (Sedan) .
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor and the module.
    3. Fig 2: Identifying Fuel Tank Vent Pipe Quick Connect Fittings
    GM1795288Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 3: Identifying Fuel Feed Pipe Retaining Features
    GM1790153Courtesy of GENERAL MOTORS CORP.
  4. Remove the fuel feed pipe from the retaining features (2, 4) built into the fuel tank.
    5. Fig 4: View Of Fuel Tank
    GM1796288Courtesy of GENERAL MOTORS CORP.
  5. Install the J 45722  to the fuel pump module lock ring.
    6. Fig 5: Identifying Fuel Sender Lock Ring
    GM1642096Courtesy 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.