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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 TANK 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: Identifying Fuel Tank Components
    GM601669Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank insulators (3).
  2. Install the fuel tank into the fuel tank shield.
    3. CAUTION: Refer to Fastener Caution .
  3. Install the fuel fill hose to the fuel tank. Tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
  4. Install the (EVAP) hoses to the fuel tank and (EVAP) canister.
  5. Install the fuel sender assembly and the fuel pipes (6) to the fuel tank and the fuel filter. Refer to Fuel Sender Assembly Replacement .
    6. Fig 2: View Of Fuel Tank (Passenger/Cargo Van)
    GM34270Courtesy of GENERAL MOTORS CORP.
  6. With the aid of an assistant, position and support the fuel tank.
  7. Raise the fuel tank slightly.
  8. Connect the fuel sender harness connector.
  9. Raise the tank fully.
  10. Install the fuel tank straps (3).
    11. NOTE: When removing or replacing the fuel tank, the fuel tank support fasteners should never be reused. Always use new fasteners when installing the fuel tank.
  11. Install the new attaching bolts (4) to the fuel tank straps and tighten to 52 N.m (39 lb ft).
  12. Connect the auxiliary heater fuel feed pipe.
  13. Connect the rear fuel feed pipe to the chassis fuel feed pipe. Refer to Metal Collar Quick Connect Fitting Service .
  14. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to Metal Collar Quick Connect Fitting Service .
    15. Fig 3: Identifying Negative Battery Cable
    GM1824281Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel fill vent hose (2) to the filler neck.
  16. Connect the fuel fill hose (1) to the fuel fill pipe and tighten to 2.75 N.m (24 lb in).
  17. Lower the vehicle.
  18. Refill the fuel tank.
  19. Tighten the fuel filler cap.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
  21. Prime the fuel system. Refer to Fuel System Priming .
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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.