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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 (WITHOUT E26)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Removal Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Removing/Installing Fuel Fill Hose Clamp & Pipe Evaporative Emission (EVAP) Line Quick Connect Fitting
    GM1944010Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027)  or Fuel Pressure Relief (Without CH 48027) .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel fill pipe evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Loosen the fuel fill hose clamp (2) at the fuel tank and remove the hose from the tank.
    6. Fig 2: Identifying Fuel Tank & EVAP Chassis Quick Connect Fittings
    GM1938257Courtesy of GENERAL MOTORS CORP.
  6. Clean the fuel and EVAP pipe connections and the surrounding areas prior to disconnecting the lines in order to avoid possible contamination of the fuel and or EVAP system.
  7. Disconnect the chassis fuel feed pipe quick connect fitting (2) from the fuel tank fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the EVAP canister purge pipe quick connect fitting (1) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid valve.
    10. Fig 3: Removing/Installing Fuel Tank
    GM1938258Courtesy of GENERAL MOTORS CORP.
  10. Support the fuel tank with an adjustable jack.
  11. Remove the fuel tank strap bolts (1).
  12. Remove the fuel tank straps (2).
  13. With the aid of an assistant, carefully lower the fuel tank (3) until the fuel tank module connections can be accessed.
  14. Disconnect the chassis wiring harness electrical connectors from the fuel tank pressure sensor and fuel tank module.
  15. With the aid of the assistant, completely lower the fuel tank.
  16. With the aid of the assistant, place the fuel tank in a suitable work area.
  17. If replacing the fuel tank proceed to the next step, otherwise proceed to step 15 in the installation procedure.
    18. Fig 4: Remove/Installing Fuel Tank Shield Push
    GM1938261Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel tank shield push on retainers (2).
  19. Remove the fuel tank shield (1) from the fuel tank clips.
    20. Fig 5: Identifying Fuel Feed Pipe Quick Connect Fitting
    GM1938263Courtesy of GENERAL MOTORS CORP.
  20. Disconnect the fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  21. Remove the fuel feed pipe from the fuel tank clips (2 and 3).
  22. Remove the fuel feed pipe (1) from under the EVAP front pipe.
    23. Fig 6: Identifying EVAP Front Pipe Quick Connect Fittings
    GM1944096Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the EVAP front pipe quick connect fittings from the fuel tank module and roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  24. Remove the EVAP front pipe (1) from under the EVAP pipe.
    25. Fig 7: Identifying EVAP Pipe Quick Connect Fitting
    GM1938268Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the EVAP pipe quick connect fitting from the fuel tank roll over valve. Refer to Plastic Collar Quick Connect Fitting Service .
  26. Remove the adhesive tape securing the EVAP pipe to the fuel tank, if necessary.
  27. Disconnect the EVAP pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  28. Disconnect the EVAP pipe quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  29. Remove the EVAP pipe (1) from the fuel tank retainers (2, 3, and 4).
  30. Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement .
  31. Remove the fuel tank module. Refer to Fuel Tank Fuel Pump Module Replacement .
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.