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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 216 (ENGINE CONTROLS AND FUEL - 3.6L - 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 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Gasoline/Gasoline Vapors Caution .
  1. Drain the fuel tank. Refer to Fuel Tank Draining .
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With High Pressure Pump - LLT) .
  3. Remove the exhaust system. Refer to Exhaust System Replacement .
  4. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement (RWD) or Rear Propeller Shaft Replacement (AWD) .
    5. Fig 1: Identifying Fuel Filler Hose & Fuel tank
    GM785808Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the filler hose (1) from the fuel tank.
  6. Disconnect the filler vent tube (2) from the evaporative emission (EVAP) hose. Refer to Plastic Collar Quick Connect Fitting Service .
    7. Fig 2: Identifying Quick-Connect Fitting At Fuel Filter Inlet
    GM785816Courtesy of GENERAL MOTORS CORP.
  7. Refer to Plastic Collar Quick Connect Fitting Service  in order to disconnect the following from the chassis bundle:
    • The fuel feed hose
    • The fuel return hose
    • The fuel EVAP hose
    8. Fig 3: View Of Fuel Tank Electrical Connector
    GM801228Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the fuel tank electrical connector.
    9. Fig 4: Identifying EVAP Hoses At EVAP Canister
    GM785817Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the EVAP hoses from the EVAP canister.
  10. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
  11. Disconnect the electrical connector from the EVAP canister.
    12. Fig 5: Supporting Control Arm Using Support Fixture
    GM708375Courtesy of GENERAL MOTORS CORP.
  12. Raise the lower control arms using a suitable screw jack (3) in order to remove the load from the lower shock bolts (2).
  13. Remove the lower shock bolts (2).
  14. Remove the screw jack (3).
    15. Fig 6: View Of Screw Jack Under Rear Frame
    GM801226Courtesy of GENERAL MOTORS CORP.
  15. Position the screw jack under the rear frame near the adjuster tie bar, in order to support the front of the rear frame.
  16. Remove the 2 front bolts from the rear frame.
    17. Fig 7: View Of Fuel Tank Strap Bolt Access Clearance
    GM801227Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

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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.