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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 4 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 4.3L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL METER BODY ASSEMBLY 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 is about a different variant/trim than selected.
IMPORTANT: All injector lines must face forward as the fuel meter body is snapped into the bracket. Also, the number 3 fuel tube must be positioned behind the number 1 fuel tube in order to eliminate interference with the upper intake manifold when installed.
    Fig 1: Injectors At Lower Intake Manifold Bores
    GM859867Courtesy of GENERAL MOTORS CORP.
  1. Position the fuel tubes of the fuel meter body in the forward position.
  2. Install the fuel meter body into the fuel meter body bracket on the lower intake manifold.
  3. Install the 6 injectors into the proper lower intake manifold bores in proper sequence (5, 1, 3, 2, 4, 6).
  4. Inspect the injectors in order to ensure that they are firmly seated and locked in the lower intake manifold bores.
  5. Ensure that the electrical connections of the injectors are positioned so that they do not interfere with each other, and are pointing towards the center of the intake manifold. Rotate the electrical connections inboard if necessary. Also, ensure there is no tension on the injector wires.
  6. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
  7. Tighten the fuel fill cap.
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  9. Test for fuel leaks using the following procedure:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. 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.