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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 TANK REPLACEMENT (WITH E26)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 variant/trim than selected.
    Fig 1: Identifying EVAP Pipe Quick Connect Fitting
    GM1938268Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .
  2. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  3. Install the EVAP pipe (1) to the fuel tank retainers (2, 3, and 4).
  4. Connect the EVAP pipe quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Connect the EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Connect the EVAP pipe quick connect fitting to the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Secure the EVAP pipe to the fuel tank with adhesive tape, if necessary.
    8. Fig 2: View Of EVAP Front Pipe Quick Connect Fittings
    GM1938265Courtesy of GENERAL MOTORS CORP.
  8. Install and route the EVAP front pipe (1) under the EVAP line.
  9. Connect the EVAP front pipe quick connect fittings to the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
    10. Fig 3: Identifying Fuel Feed Pipe Quick Connect Fitting
    GM1938263Courtesy of GENERAL MOTORS CORP.
  10. Install and route the fuel feed pipe (1) under the EVAP front pipe.
  11. Connect the fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Install the fuel feed pipe to the fuel tank clips (2 and 3).
    13. Fig 4: Remove/Installing Fuel Tank Shield Push
    GM1938261Courtesy of GENERAL MOTORS CORP.
  13. Install the fuel tank shield onto the tank clips (1).
  14. Install the fuel tank shield push on retainers (2).
    15. Fig 5: Removing/Installing Fuel Tank
    GM1938258Courtesy of GENERAL MOTORS CORP.
  15. With the aid of an assistant, place the fuel tank on the adjustable jack.
  16. With the aid of the assistant, carefully raise the fuel tank (3) until the fuel tank module connections can be made.
  17. Connect the chassis wiring harness electrical connectors to the fuel tank pressure sensor and fuel tank module.
  18. With the aid of the assistant, completely raise the fuel tank.
  19. Install the fuel tank straps (2).
    20. NOTE: Refer to Fastener Notice .
  20. Install the fuel tank strap bolts (1).

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  21. Remove the adjustable jack from under the fuel tank.
    22. Fig 6: Identifying Fuel Tank & EVAP Chassis Quick Connect Fittings
    GM1938257Courtesy of GENERAL MOTORS CORP.
  22. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid valve.
  23. Connect the EVAP canister purge pipe quick connect fitting (1) to the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Connect the fuel feed pipe quick connect fitting (2) to the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
    25. Fig 7: Removing/Installing Quick Connect Fitting
    GM1938255Courtesy of GENERAL MOTORS CORP.
  25. Install the fuel tank fill hose to the fuel tank.
  26. Connect the fuel fill pipe EVAP line quick connect fitting (1) to the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  27. Tighten the fuel fill hose clamp (2) at the fuel tank.

    Tighten:  Tighten the clamp to 2.75 N.m (24 lb in).

  28. Refill the fuel tank.
  29. Install the fuel cap.
  30. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  31. Perform the following procedure in order to inspect for leaks:
    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.