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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 PUMP REPLACEMENTINSTALLATION 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 Injection Pump
    GM1336114Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injection pump to the block.
  2. Install the fuel injection pump bolts and tighten to 21 N.m (15 lb ft).
  3. Install the hoses to fuel lines.
  4. Position the injection pump hose clamps at the fuel line.
  5. Connect the injection pump electrical connector.
  6. Install the center intake manifold. Refer to Center Intake Manifold Replacement (LMM) .
  7. Install the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side .
  8. Install the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side .
  9. Install the thermostat housing crossover.
    10. Fig 2: Identifying Wiring Harness Retainer
    GM1601448Courtesy of GENERAL MOTORS CORP.
  10. Prime the fuel system. Refer to Fuel System Priming .
  11. Start the engine.

    If the engine stalls, repeat the above step.

  12. Once the engine starts, inspect for fuel leaks.
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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.