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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 537 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.8L, 5.3L OR 6.0L - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENT (PASSENGER/CARGO)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 does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of fuel tank
    GM1822370Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank into the fuel tank shield (3).
    2. CAUTION: Refer to Fastener Caution .
  2. Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  3. On models with EVAP canister mounted to fuel tank, place the (EVAP) canister in position on the (EVAP) canister bracket, then install two new tiedown straps.
  4. On all models, install the (EVAP) hoses to the fuel tank.
  5. Install the fuel tank module (1) and the fuel pipes to the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement .
    6. Fig 2: View Of fuel sender
    GM1823416Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the electrical connectors to the fuel tank module and fuel pump.
  9. Raise the tank fully.
  10. Install the fuel tank straps (2).
    11. NOTE: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
  11. Install the new attaching bolts (1) to the fuel tank strap and tighten the bolts to 20.5 N.m (15 lb ft).
    12. Fig 3: View Of fuel fill hose
    GM1823384Courtesy of GENERAL MOTORS CORP.
  12. Connect the chassis fuel feed pipe to the rear fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  13. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  14. Connect the fuel fill vent hose (2) to the filler tube.
  15. Connect the fuel fill hose (1) to the fuel tank and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  16. Lower the vehicle.
  17. Refill the fuel tank.
  18. Tighten the fuel filler cap.
  19. Inspect for leaks:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
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.