Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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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 INSTRUCTIONSFUEL TANK FUEL PUMP MODULE REPLACEMENTINSTALLATION 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 Fuel Tank Module

Courtesy of GENERAL MOTORS CORP.

Install a NEW fuel tank module O-ring seal (3) onto the fuel tank.

NOTE: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

Tilt the module toward the left side of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
Lower the module assembly (2) into the tank.
Position and install the fuel tank module lock ring (1).

Fig 2: View Of Fuel Tank Module Lock Ring

Courtesy of GENERAL MOTORS CORP.

Install the J 45722 (1) to the fuel tank module lock ring. See Special Tools .

Fig 3: Identifying Lock Ring

Courtesy 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.