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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 443 (ENGINE CONTROLS AND FUEL - 4.6L - INTRODUCTION)REPAIR INSTRUCTIONSSECONDARY FUEL TANK MODULE 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 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
    WARNING: Refer to Gasoline/Gasoline Vapors Warning .
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
    2. Fig 1: View Of Secondary Fuel Tank Module Electrical Connector
    GM820625Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the electrical connector from the secondary fuel tank module.
    3. Fig 2: Rotating Cam Lock Ring Using Special Tool
    GM820626Courtesy of GENERAL MOTORS CORP.
  3. Rotate the cam lock ring counterclockwise using the J 45747  .
  4. Remove the cam lock ring from the fuel tank.
    5. Fig 3: View Of Secondary Fuel Tank Module & Transfer Tube
    GM820620Courtesy of GENERAL MOTORS CORP.
  5. Carefully lift the secondary fuel tank module (2) from the fuel tank only enough to access the transfer tube (1).
    6. Fig 4: View Of Transfer Tube Locking Mechanism
    GM820621Courtesy of GENERAL MOTORS CORP.
  6. Complete the following in order to disconnect the transfer tube from the secondary fuel tank module.
    1. Pull the locking mechanism away from the module.
    2. Remove the transfer tube from the module.
    7. Fig 5: View Of Secondary Fuel Tank Module
    GM820627Courtesy of GENERAL MOTORS CORP.
  7. Remove the secondary fuel tank module from the fuel tank.
  8. Remove the secondary fuel tank module seal from the module.

    Do not reuse the seal.

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.