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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 REPLACEMENTREMOVAL 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 Left Fuel Rail At Pump Pipe
    GM1335603Courtesy of GENERAL MOTORS CORP.
  1. Remove the thermostat housing crossover.
  2. Remove the left fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Left Side .
  3. Remove the right fuel rail fuel feed pipe. Refer to Fuel Injection Fuel Feed Front Pipe Replacement - Right Side .
  4. Remove the center intake manifold. Refer to Center Intake Manifold Replacement (LMM) .
  5. Disconnect the injection pump electrical connector.
    6. Fig 2: View Of Fuel Hose Connections
    GM1335595Courtesy of GENERAL MOTORS CORP.
  6. Compress the injection pump hose clamps at the fuel line.
  7. Disconnect the hoses from fuel lines.
    8. Fig 3: View Of Fuel Injection Pump
    GM1336114Courtesy of GENERAL MOTORS CORP.
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.