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HOMESERVICE MANUALSCHEVROLET2012CHEVY EXPRESS G2500, VAN PASSENGER, 4.8L ENG VIN AREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 996 (ENGINE CONTROLS AND FUEL - 4.8L, 5.3L, 6.0L, 6.2L, OR 7.0L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL TANK FUEL PUMP MODULE REPLACEMENT (15/25 REG/EXT/CREW CAB W/34 GAL TANK)INSTALLATION PROCEDURE
2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN A

Installation Procedure

2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN ASECTION Installation Procedure
WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Pump Module & Lock Ring
    GM1854933Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW fuel tank module O-ring seal onto the fuel tank.
    2. IMPORTANT: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.
  2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  3. Lower the module assembly into the tank.
  4. Position and install the fuel tank module lock ring.
  5. Ensure that the module sealing surface is clean and free of contamination.
    6. Fig 2: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
  6. Install the J 45722  to the fuel tank module lock ring.
    7. IMPORTANT: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.
    Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  7. Using the J 45722  and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.
    8. Fig 3: Special Tool On Fuel Tank Module Lock Ring
    GM1854932Courtesy of GENERAL MOTORS CORP.
  8. Remove the J 45722  (1) from the fuel tank module lock ring.
  9. Position the fuel and EVAP pipes to the module.
  10. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Install the fuel tank. Refer to Fuel Tank Replacement (15 Reg Cab w/26 Gal Tank)  or Fuel Tank Replacement (25 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Replacement (15 Ext/Crew Cab w/26 gal Tank)  or Fuel Tank Replacement (15/25 Reg/Ext/Crew Cab w/34 gal Tank)  or Fuel Tank Replacement (35 Reg/Ext/Crew Cab w/34 gal Tank) .
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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.