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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 TANK REPLACEMENT (SEDAN)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation 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: View Of Fuel Tank Strap Bolts
    GM1789404Courtesy of GENERAL MOTORS CORP.
  1. Have assistants support either side of the fuel tank.
  2. If applicable, begin to install the right side of the fuel tank over the muffler assembly.
  3. If applicable, raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP line wiring harness over the muffler assembly.
  4. If applicable and the muffler assembly was removed, have assistants raise the fuel tank into position.
  5. Install fuel tank straps and bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    6. Fig 2: Identifying Muffler Insulators And Hangers
    GM1787811Courtesy of GENERAL MOTORS CORP.
  6. Raise the muffler assembly into position if applicable, otherwise install 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) .
  7. With the aid of an assistant, install the muffler insulators (1) to the underbody hangers.
  8. Remove the jackstand from under the muffler assembly.
    9. Fig 3: View Of Fuel Fill Pipe Hose & EVAP Emission Pipe
    GM1789403Courtesy of GENERAL MOTORS CORP.
  9. Install the fuel fill pipe hose to the fuel tank.
  10. Connect 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 .
  11. Tighten the fuel fill pipe hose clamp (3) at the fuel tank.

    Tighten:  Tighten the clamp to 4 N.m (35 lb in).

    12. Fig 4: Identifying Fuel Tank & Chassis Fuel Feed Pipe
    GM1789402Courtesy of GENERAL MOTORS CORP.
  12. Remove the caps from the fuel and EVAP pipes.
  13. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
    15. Fig 5: Identifying ABS Wiring Harness Electrical Connectors
    GM1789401Courtesy of GENERAL MOTORS CORP.
  15. Install the rear ABS wiring harness clip to the EVAP canister.
  16. Connect the body wiring harness electrical connector (1) to the rear ABS wiring harness electrical connector (2).
  17. Install the rear ABS wiring harness electrical connector (2) clip to the EVAP canister.
    18. Fig 6: View Of Fuel Tank Fuel Pump Module Wiring Harness Electrical Connector
    GM1789400Courtesy of GENERAL MOTORS CORP.
  18. Connect the body wiring harness electrical connector (2) to the fuel tank fuel pump module wiring harness electrical connector.
  19. Install the body wiring harness electrical connector clip (1) to the underbody.
  20. Lower the vehicle.
  21. Refill the fuel tank.
  22. Tighten the fuel fill cap.
  23. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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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.