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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 536 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.3L - INTRODUCTION)REPAIR INSTRUCTIONSFILLER TUBE REPLACEMENT (WITH E26)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 2009 GMC Savana and 2009 Chevrolet Chevy Express. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Quick Connect Fitting, Fuel Fill Pipe & Hose Clamp
    GM1943757Courtesy of GENERAL MOTORS CORP.
  1. Remove the cap from the fuel tank inlet.
  2. Install the fuel fill pipe (2) to the fuel tank.
    3. CAUTION: Refer to Fastener Caution .
  3. Tighten the fuel fill pipe hose clamp (1) at the fuel tank to 2.75 N.m (24 lb in).
  4. Connect the fuel fill pipe EVAP pipe quick connect fitting (3) to the fuel tank EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 2: Identifying Fuel Tank Fill Pipe Housing Bolts
    GM1943754Courtesy of GENERAL MOTORS CORP.
  5. Position the ground strap and install the fuel fill tube ground strap bolt and tighten to 8 N.m (70 lb in).
  6. Lower the vehicle.
  7. Position the fuel fill pipe to the housing and install the 3 fuel tank fill pipe to housing bolts (1). Tighten to 4 N.m (35 lb in).
  8. Fill the fuel tank as necessary. Refer to Fuel Tank Draining (with L59)  or Fuel Tank Draining (without L59) .
  9. Install the fuel fill cap.
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.