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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 - CHASSISREMOVAL 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 Line Bracket & Nut
    GM1378748Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Disconnect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service .
  3. Remove the fuel line bracket nut.
  4. Remove the fuel line bracket from the stud.
  5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
    6. Fig 2: Fuel Bundle Clips & Transmission Brackets
    GM737687Courtesy of GENERAL MOTORS CORP.
  6. Remove the fuel bundle clips (2) from the transmission brackets (1).
  7. Disconnect the chassis harness from the retaining clips.
  8. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .
    9. Fig 3: View Of Fuel Feed And Return Lines At Fuel Tank (Pickup)
    GM1228124Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
    10. Fig 4: View Of Fuel Pipe Bundle (Cab/Chassis)
    GM1228212Courtesy of GENERAL MOTORS CORP.
  10. Remove the fuel bundle nuts from the chassis.
    11. Fig 5: View Of EBCM/EHCU Assembly
    GM379478Courtesy of GENERAL MOTORS CORP.
  11. Loosen the electronic brake control module (EBCM) bracket bolts (4).
  12. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
  13. Remove the fuel bundle using the following procedure:
    1. Guide the fuel bundle pipes towards the rear of vehicle to clear the engine.
    2. Lower the fuel bundle while moving it foreword and out.
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.