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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 651 (ENGINE CONTROLS AND FUEL - 3.6L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSFUEL FEED INTERMEDIATE PIPE REPLACEMENT (LLT)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2010 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Ensure that the high pressure fuel pipe, fuel rail fitting and fuel pump fitting are clean and dry prior to assembly.
  2. Lubricate the pipes with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    3. Fig 1: High Pressure Pipe Fitting, Left Fuel Rail & High Pressure Fuel Pipe
    GM1977757Courtesy of GENERAL MOTORS CORP.
  3. Position the NEW high pressure fuel pipe (2) to the high pressure fuel pump fitting (1) and left fuel rail (3). Hand tighten the fitting.
    4. CAUTION: Refer to Fastener Caution .
  4. Tighten the high pressure fuel pipe fitting.
    1. Tighten the fitting a first pass to 16 N.m (12 lb ft).
    2. Tighten the fitting a final pass to 32 N.m (24 lb ft).
    5. NOTE: If a fuel leak accrues at the high pressure fuel pump or the fuel rail, that component will need to be replaced.
  5. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  6. Install the low side fuel pressure service port cap.
  7. Install the fuel tank cap.
  8. Install the high pressure pump shield. Refer to Fuel Pipe Shield Replacement (LLT) .
  9. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement (LLT) .
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.