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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 225 (ENGINE CONTROLS AND FUEL - 4.6L (LH2) - INTRODUCTION)REPAIR INSTRUCTIONSFUEL SYSTEM CLEANINGREMOVAL 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.
  1. Remove the in-line fuel filter. Refer to Fuel Filter Replacement .
  2. Inspect the fuel system for contamination of the in-line fuel filter. Replace the filter after cleaning the fuel lines if the filter is plugged or contaminated.
  3. Remove the fuel module assemblies. Refer to Primary Fuel Tank Module Replacement  and Secondary Fuel Tank Module Replacement .
  4. Locate the tank in a suitable work area away from any heat, any flame, or any other source of ignition.
  5. Perform the following procedures:
    • Inspect the fuel sender strainer. Replace the primary fuel tank module if the strainer is contaminated.
    • Inspect the secondary fuel tank module for debris. Clean the secondary fuel tank module if debris is found.
      • CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
    • Use compressed air in order to apply air pressure to the transfer tube.
    6. IMPORTANT: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local, state, and federal laws and regulations.
  6. Flush the fuel tank with running hot water for at least five minutes. Pour the water out of the fuel sender assembly opening. Rock the tank in order to ensure that the removal of the water from the tank is complete.
  7. Disconnect the fuel feed hose/pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  8. Use compressed air in order to apply air pressure to the fuel lines in the opposite direction from the normal fuel flow.
  9. Remove the fuel injectors and fuel rail. Refer to Fuel Injector and Fuel Rail Replacement .
  10. Clean and inspect the fuel injectors and fuel rail.
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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.