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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 INJECTION FUEL RAIL ASSEMBLY REPLACEMENT - BANK 2REMOVAL 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.
  1. Remove the engine cover. Refer to Engine Cover Replacement .
  2. Remove the air conditioning (A/C) compressor. Refer to Air Conditioning Compressor Replacement (6.6L) .
  3. Remove the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side .
  4. Remove the right fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side .
  5. Remove the left fuel injector feed pipes. Refer to Fuel Injection Fuel Feed Pipe Replacement - Left Side .
    6. Fig 1: Identifying intake air temperature sensor
    GM1732300Courtesy of GENERAL MOTORS CORP.
  6. Disconnect the fuel rail temperature (FRT) sensor electrical connector.
  7. Remove the fuel return pipe. Refer to Fuel Return Pipe Replacement .
    8. Fig 2: Identifying LH fuel rail
    GM1732079Courtesy of GENERAL MOTORS CORP.
  8. Remove the 2 fuel rail bolts and the fuel rail assembly.
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.