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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 538 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 6.6L LMM - INTRODUCTION)REPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - CHASSISINSTALLATION 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 Pipe Bundle (Cab/Chassis)
    GM1228212Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel pipe bundle using the following procedure:
    1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle.
    2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections.
    2. CAUTION: Refer to Fastener Caution .
  2. Install the fuel bundle nuts to the chassis and tighten to 16 N.m (12 lb ft).
    3. Fig 2: View Of Fuel Feed And Return Lines At Fuel Tank (Pickup)
    GM1228124Courtesy of GENERAL MOTORS CORP.
  3. Connect the fuel feed and return lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .
    5. Fig 3: Fuel Bundle Clips & Transmission Brackets
    GM737687Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel bundle clips (2) to the transmission brackets (1).
    6. Fig 4: View Of EBCM/EHCU Assembly
    GM379478Courtesy of GENERAL MOTORS CORP.
  6. Tighten the EBCM bracket bolts (4) and tighten to 25 N.m (18 lb ft).
  7. Lower the vehicle.
    8. Fig 5: View Of Fuel Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel line bracket to the stud.
  9. Install the fuel line bracket nut and tighten to 16 N.m (12 lb ft).
  10. Connect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service .
  11. Prime the fuel system. Refer to Fuel System Priming .
  12. Start the engine. If the engine stalls, repeat the above step.
  13. Once the engine starts, inspect for fuel leaks.
  14. Install the engine cover. Refer to Engine Cover Replacement .
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.