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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)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal 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 fill hose
    GM1823384Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) or Fuel Pressure Relief (Without CH-48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining (with L59)Fuel Tank Draining (w/o L59) .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
  5. Loosen the fuel fill hose clamp.
  6. Disconnect the fuel fill hose (1) from the filler tube.
  7. Disconnect the fuel fill vent hose (2) from the filler tube.
  8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    10. Fig 2: View Of fuel sender
    GM1823416Courtesy of GENERAL MOTORS CORP.
  10. With the aid of an assistant, support the fuel tank.
  11. Remove and discard the attaching bolts (1) from the fuel tank strap.
  12. Remove the fuel tank straps (2).
  13. Carefully lower the fuel tank.
  14. Disconnect the fuel tank module and the fuel pump electrical connectors.
  15. Remove the fuel tank.
  16. Place the fuel tank in a suitable work area.
    17. Fig 3: View Of fuel tank
    GM1822370Courtesy of GENERAL MOTORS CORP.
  17. Remove the fuel tank module (1) and the fuel pipes from the fuel tank. Refer to Fuel Tank Fuel Pump Module Replacement .
  18. Remove the evaporative emission (EVAP) hoses from the fuel tank.
  19. On models with EVAP canister mounted to fuel tank, remove two tiedown straps from the (EVAP) canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
  20. On all models, remove the fuel fill hose from the fuel tank.
  21. Remove the fuel tank from the fuel tank shield (3).
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.