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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 445 (ENGINE CONTROLS AND FUEL - 4.4L - INTRODUCTION)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 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. Drain the fuel tank. Refer to Fuel Tank Draining .
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027)  or Fuel Pressure Relief (Without CH 48027) .
  3. Remove the exhaust system. Refer to Exhaust System Replacement .
  4. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement (AWD) or Rear Propeller Shaft Replacement (RWD) .
    5. Fig 1: Identifying Fuel Filler Hose To 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 Fuel Filter
    GM1653564Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel feed hoses (4 and 5) from the fuel filter. Refer to Metal Collar Quick Connect Fitting Service .
  8. Disconnect the fuel EVAP hose (6) from the chassis bundle. Refer to Plastic Collar Quick Connect Fitting Service .
    9. Fig 3: View Of Fuel Tank Electrical Connector
    GM801228Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank electrical connector.
    10. Fig 4: Identifying EVAP Hoses At EVAP Canister
    GM785817Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the EVAP hoses from the EVAP canister.
  11. Pull outward on the retainer tab in order to disengage the retainer from the chassis.
  12. Disconnect the electrical connector from the EVAP canister vent solenoid valve.
  13. Disconnect the fuel tank pressure sensor electrical connector from the EVAP canister.
    14. Fig 5: Identifying Fuel Filter
    GM1653564Courtesy of GENERAL MOTORS CORP.
  14. Remove the bolt (7) from the right side rear suspension bracket brace.
  15. Loosen the nut (8) and allow the brace to swing downward. This will provide clearance while lowering the rear frame.
    16. Fig 6: Identifying Left Side Rear Suspension Bracket Brace
    GM1614625Courtesy of GENERAL MOTORS CORP.
  16. Remove the bolt (1) from the left side rear suspension bracket brace.
  17. Loosen the nut (2) and allow the brace to swing downward. This will provide clearance while lowering the rear frame.
    18. Fig 7: Identifying Support Fixture Components
    GM708375Courtesy of GENERAL MOTORS CORP.
  18. Raise the lower control arms using a suitable screw jack (3) in order to remove the load from the lower shock bolts (2).
  19. Remove the lower shock bolts (2).
  20. Remove the screw jack (3).
    21. Fig 8: View Of Screw Jack Under Rear Frame
    GM801226Courtesy of GENERAL MOTORS CORP.
  21. Position the screw jack under the rear frame near the adjuster tie bar, in order to support the front of the rear frame.
  22. Remove the 2 front bolts from the rear frame.
    23. Fig 9: 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.