Engine Controls/fuel - 4.8l (l20), 5.3l (Lmf), or 6.0l (l96 lc8) - Repair Instructions Chevrolet Express H1500

Brake Pedal Position Sensor Learn

Brake Pedal Position Sensor Learn is a procedure for the ECM to determine the position of the brake pedal position sensor when the brake pedal is in the released position.

1. An Engine Control Module Replacement
2. A BPP Sensor Replacement
3. Any repair procedure that effects the brake pedal position sensor alignment

1. Install a scan tool.
2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-h1500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
3. Navigate to the scan tool Brake Pedal Position Sensor Learn command by selecting the following: Module Diagnosis Engine Control Module Configuration/Reset Functions Learn Functions Brake Pedal Position Sensor Learn
4. Ignition ON, Engine OFF, transmission in Park, brake pedal in the fully released position, select Learn.
5. Verify Brake Pedal Position Sensor and Brake Pedal Position Sensor Learned Home Position are within .1 Volts.
6. Select Exit.
7. Perform the body control module (BCM) brake pedal position sensor calibration. Refer to «Brake Pedal Position Sensor Calibration»(/chevrolet/express-h1500/2013-2013/remont/exterior-lights/#lighting-system__brake-pedal-position-sensor-calibration) .

Removal Procedure

Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM.

Note. Before removing the ECM, use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW ECM. Refer to Control Module References .

1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect the engine wiring harness electrical connectors (2) from the ECM (1).
4. Release the ECM bracket tabs (3).
5. Remove the ECM (4) from the bracket (2).

Installation Procedure

1. Install the ECM (4) to the bracket (2).
2. Ensure that the ECM bracket tabs (3) fully engage the ECM.
3. Connect the engine wiring harness electrical connectors (2) to the ECM (1).
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. If a new ECM was installed, program the ECM. Refer to «Control Module References»(/chevrolet/express-h1500/2013-2013/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
6. Using a scan tool, set the remaining engine oil life.

Crankshaft Position System Variation Learn

Note. The Crankshaft Position System Variation Learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: A crankshaft position sensor replacement An engine control module (ECM) replacement An engine replacement A crankshaft balancer replacement A crankshaft replacement Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship.

Note. The ECM monitors certain component signals to determine if all the conditions are met to continue with the Crankshaft Position System Variation Learn Procedure.

1. Ignition ON, observe the DTC information with a scan tool. Verify no other DTCs are set, except DTCs P0300-P0304, or P0315. If DTCs are set, except DTCs P0300-P0304, or P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-h1500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for further diagnosis.
2. Select the Crankshaft Position Variation Learn Procedure with a scan tool and follow the on screen instructions
3. Verify DTC P0315 does not set. If DTC P0315 set, or another DTC is present refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/express-h1500/2013-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set. If the DTC does not set
4. All OK.

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

Scan tool Idle Learn or Idle Learn Reset Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201-P0208, P0220, P0222, P0223, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P0277, P0279, P0280, P0282, P0283, P0300-P0308, P0351-P0358, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. Ignition ON, engine OFF.
3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Service Bay/On Road Learn Procedure

1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201-P0208, P0220, P0222, P0223, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P0277, P0279, P0280, P0282, P0283, P0300-P0308, P0351-P0358, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
2. The engine speed is between 450-4,000 RPM.
3. The manifold absolute pressure (MAP) is greater than 5 kPa.
4. The mass air flow (MAF) is greater than 2 g/s.
5. The ignition voltage is greater than 10 volts.

Throttle Learn

Scan Tool Idle Learn or Idle Learn Reset Procedure - Performed after the throttle body is cleaned or replaced

1. Ignition ON, engine OFF, perform the Idle Learn or Idle Learn Reset in Configuration/Reset or Module Setup.
2. Engine idling, observe the scan tool Throttle Body Idle Airflow Compensation parameter. The Throttle Body Idle Airflow Compensation value should equal 0 % and the engine should be idling at a normal idle speed.
3. Clear the DTCs and return to the diagnostic that referred you here.

Service Bay/On Road Idle Learn Procedure - Performed after the ECM is programmed or replaced

1. Engine idling for 3 minutes.
2. Observe the scan tool Desired Idle Speed and the actual Engine Speed parameters.
3. The ECM will start to learn the new idle cells and the Desired Idle Speed should start to decrease.
4. Ignition OFF for 60 seconds.
5. Start and idle the engine for 3 minutes.
6. After the 3 minute run time the engine should be idling normal. NOTE: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
7. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

1. Turn OFF the ignition.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Drain the cooling system below the level of the ECT sensor. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .
4. Lower the vehicle.
5. Disconnect the electrical connector from the engine coolant temperature (ECT) sensor.
6. Remove the ECT sensor.

1. If reusing the ECT sensor, coat the ECT sensor threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or the equivalent.
2. Install the ECT sensor and tighten to 20 N.m (15 lb ft).
3. Connect the ECT sensor electrical connector.
4. Refill the engine coolant. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) .

Note. Take care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. Do not drop or roughly handle the MAF/IAT sensor.

1. Disconnect the MAF/IAT sensor electrical connector (1).
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Loosen the clamp securing the MAF/IAT sensor to the air cleaner duct.
4. Remove the MAF/IAT sensor bolts from the air cleaner assembly.
5. Remove the MAF/IAT from the air cleaner.

Note. The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine.

1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
2. Install the MAF/IAT sensor onto the air cleaner housing.
3. Install the MAF/IAT sensor retaining bolts and tighten to 11 N.m (97 lb in).
4. Tighten the clamp securing the MAF/IAT sensor to the air cleaner duct.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
6. Connect the MAF/IAT electrical connector (1).

Scheme 46

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
3. Remove the MAP sensor (1) from the intake manifold.

1. Install the MAP sensor to the upper intake manifold.
2. Connect the MAP sensor electrical connector.
3. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Scheme 47

Heated Oxygen Sensor Replacement - Bank 1 Sensor 1

Scheme 48

Heated Oxygen Sensor Replacement - Bank 1 Sensor 2

Scheme 49

Heated Oxygen Sensor Replacement - Bank 2 Sensor 1

Scheme 50

Heated Oxygen Sensor Replacement - Bank 2 Sensor 2

1. Remove the connector position assurance (CPA) retainer.
2. Disconnect the electrical connector from the accelerator pedal position (APP) sensor.
3. Remove the accelerator pedal bolt (1).
4. Remove the accelerator pedal assembly (1) from the dash panel.

1. Install the accelerator pedal assembly (1) to the dash panel.
2. Install the accelerator pedal bolt (1) and tighten to 33 N.m (24 lb ft).
3. Connect the electrical connector to the APP sensor.
4. Install the CPA retainer.
5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
7. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.

Scheme 51

Throttle Body Assembly Replacement

Throttle Body Cleaning

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) . WARNING: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. CAUTION: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. CAUTION: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626, or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Perform the Throttle/Idle Learn procedure. Refer to «Q38 Throttle Body: Throttle/Idle Learn»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Fuel Pressure Gauge Installation and Removal

Special Tools

CH-48027 Digital Pressure Gauge

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027 Digital Pressure Gauge , refer to the manufacturers directions.

1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
4. Disconnect the CH-48027-3 (4) from the fuel rail service port.
5. Install the fuel rail service port cap.
6. Install the engine cover, if required.
7. Tighten the fuel fill cap.

Fuel Pressure Relief (CH-48027)

Special Tools

CH-48027 Digital Pressure Gauge

1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/chevrolet/express-h1500/2013-2013/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
2. Remove the engine cover, if required.
3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port.
6. Connect the CH-48027-3 (4) to the fuel rail service port.
7. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
8. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
10. Close the valve on the CH-48027-2 (2).
11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
12. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
13. Disconnect the CH-48027-3 (4) from the fuel rail service port.
14. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
15. Install the fuel rail service port cap.
16. Install the engine cover, if required.
17. Tighten the fuel fill cap.

Fuel Pressure Relief (Without CH-48027)

1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/chevrolet/express-h1500/2013-2013/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
3. Remove the engine cover, if required.
4. Remove the fuel rail service port cap.
5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve.
6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
7. Install the fuel rail service port cap.
8. Install the engine cover, if required.
9. Tighten the fuel fill cap.

Metal Collar Quick Connect Fitting Service

Special Tools

J 37088-A Fuel Line Quick-Connect Separator, Tool Set

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Remove the retainer from the quick-connect fitting.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 37088-A Fuel Line Quick-Connect Separator, Tool Set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
5. Pull the connection apart.
6. Use a clean shop towel in order to wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

1. Apply a few drops of clean engine oil to the male pipe end.
2. Push both sides of the fitting together in order to snap the retaining tabs into place.
3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
4. Install the retainer to the quick-connect fitting.

1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. Squeeze the plastic retainer release tabs.
4. Pull the connection apart.

1. Apply a few drops of clean engine oil to the male fuel pipe end.
2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
3. Once installed, pull on both sides of the quick-connect fitting in order to make sure the connection is secure.

Scheme 52

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the chassis wiring harness electrical connector (2) from the fuel pump flow control module (1).
3. Remove the fuel pump flow control module bolts (1).
4. Remove the fuel pump flow control module (2) from the frame.

1. Place the fuel pump flow control module (2) against the frame.
2. Install the fuel pump flow control module bolts (1) and tighten to 9 N.m (80 lb in).
3. Connect the chassis wiring harness electrical connector (1) to the fuel pump flow control module (2).
4. Lower the vehicle.
5. Program the fuel pump flow control module. Refer to «Control Module References»(/chevrolet/express-h1500/2013-2013/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

Fuel Tank Draining (L59)

1. Remove the fuel filler cap.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Clean the area around the fuel filler pipe to tank connection.
4. Place a drain pan under the fuel filler pipe connection.
5. Disconnect the fuel fill hose (1) at the fuel tank.
6. Use a hand or air operated pump device in order to drain as much fuel through the fuel tank filler pipe opening as possible.
7. If not removing the fuel tank, connect the fuel fill hose to the fuel tank and tighten the clamp to 2.75 N.m (24 lb in).

Fuel Tank Draining (Without L59)

1. Remove the fuel filler cap.
2. Use a hand or air operated pump device in order to drain as much fuel through the fuel tank filler pipe opening as possible.

1. Remove the fuel filler cap.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Clean the area around the fuel filler pipe to tank connection.
4. Place a drain pan under the fuel filler pipe connection.
5. Disconnect the fuel fill hose (1) at the fuel tank.
6. Use a hand or air operated pump device in order to drain as much fuel through the fuel tank filler pipe opening as possible.
7. If not removing the fuel tank, connect the fuel fill hose to the fuel tank and tighten the clamp to 2.75 N.m (24 lb in).

1. Remove the fuel filler cap.
2. Use a hand or air operated pump device in order to drain as much fuel through the fuel tank filler pipe opening as possible.

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
2. Remove the fuel filler cap.
3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
6. Remove the fuel filler tube ground strap bolt.
7. Loosen the fuel fill hose to fuel fill pipe clamp.
8. Disconnect the fuel fill hose from the fuel fill pipe.
9. Remove the fuel fill pipe assembly.

1. Install the fuel fill pipe to the fuel fill hose.
2. Align the fuel fill pipe to the fuel fill pipe housing and tighten the clamp to 2.75 N.m (24 lb in).
3. Install the fuel filler tube ground strap bolt and tighten the bolt to 8 N.m (70 lb in).
4. Lower the vehicle.
5. Install the fuel fill pipe housing bolts and push-pin and tighten the bolts to 6 N.m (53 lb in).
6. Refill the fuel tank.
7. Install the fuel filler cap.

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
2. Remove the fuel filler cap.
3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
6. Remove the fuel filler tube ground strap bolt.
7. Loosen the fuel fill hose to fuel fill pipe clamp.
8. Disconnect the fuel fill hose from the fuel fill pipe.
9. Remove the fuel fill pipe assembly.

1. Install the fuel fill pipe to the fuel fill hose.
2. Align the fuel fill pipe to the fuel fill pipe housing and tighten the clamp to 2.75 N.m (24 lb in).
3. Install the fuel filler tube ground strap bolt and tighten the bolt to 8 N.m (70 lb in).
4. Lower the vehicle.
5. Install the fuel fill pipe housing bolts and push-pin and tighten the bolts to 6 N.m (53 lb in).
6. Refill the fuel tank.
7. Install the fuel filler cap.

1. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid contamination of the fuel system.
2. Remove the fuel filler cap.
3. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the 2 retaining bolts and push-pin that retain the filler neck to the body.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
6. Remove the fuel filler tube ground strap bolt.
7. Loosen the fuel fill hose to fuel fill pipe clamp.
8. Disconnect the fuel fill hose from the fuel fill pipe.
9. Remove the fuel fill pipe assembly.

1. Install the fuel fill pipe to the fuel fill hose.
2. Align the fuel fill pipe to the fuel fill pipe housing and tighten the clamp to 2.75 N.m (24 lb in).
3. Install the fuel filler tube ground strap bolt and tighten to 8 N.m (70 lb in).
4. Lower the vehicle.
5. Install the fuel fill pipe housing bolts and push-pin and tighten the bolts to 6 N.m (53 lb in).
6. Refill the fuel tank.
7. Install the fuel filler cap.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
3. Raise the vehicle. This must be done with a frame hoist in order to allow the rear suspension to hang. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the fuel fill hose (1) from the fuel fill tube.
5. Disconnect the fuel fill vent hose (2) from the fuel fill tube.
6. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
7. Disconnect the rear fuel and evaporative emissions (EVAP) pipes (2) at the chassis fuel and EVAP pipes. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
8. Cap the fuel and EVAP pipes in order to prevent fuel system contamination.
9. With the aid of an assistant, support the fuel tank.
10. Remove the attaching bolts (4) from the fuel tank straps. Discard attaching bolts.
11. Remove the fuel tank straps (3) and two fuel tank strap insulators.
12. Carefully lower the fuel tank.
13. Disconnect the electrical connectors from the fuel tank module and the fuel pressure sensor.
14. Remove the fuel tank.
15. Place the fuel tank in a suitable work area.
16. Remove the fuel fill hose and fuel fill vent hose from the fuel tank.
17. Remove the fuel tank module and the rear fuel and EVAP pipes from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .

1. Install the fuel tank insulators.
2. Install the fuel tank module and the rear fuel and EVAP pipes to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
3. Install the fuel fill hose and fuel fill vent hose to the fuel tank.
4. With the aid of an assistant, position and support the fuel tank.
5. Raise the fuel tank slightly.
6. Connect the electrical connectors to the fuel tank module and the fuel pressure sensor .
7. Raise the tank fully.
8. Install the fuel tank straps (3).
9. Install the new attaching bolts (4) to the fuel tank straps and tighten the bolts to 20.5 N.m (15 lb ft).
10. Remove the caps from the fuel and EVAP pipes.
11. Connect the rear fuel and EVAP pipes (2) to the chassis fuel and EVAP pipes. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
12. Connect the fuel fill vent hose (2) to the full pipe.
13. Connect the fuel fill hose to the fuel tank (1) and tighten the fuel fill hose clamp (2) to 2.75 N.m (24 lb in).
14. Lower the vehicle.
15. Refill the fuel tank.
16. Tighten the fuel filler cap.
17. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition . Inspect for fuel leaks.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Clean all fuel pipe and hose connections and surrounding areas before disconnecting the fuel pipes in order to avoid contamination of the fuel system.
5. Loosen the fuel fill hose clamp.
6. Disconnect the fuel fill hose (1) from the fuel fill pipe.
7. Disconnect the fuel fill vent hose (2) from the fill pipe.
8. Disconnect the rear evaporative emission (EVAP) pipe at the EVAP canister.
9. With the aid of an assistant, support the fuel tank.
10. Remove the attaching bolts (1) from the fuel tank straps. Discard attaching bolts.
11. Remove the fuel tank straps (2).
12. Carefully lower the fuel tank.
13. Disconnect the fuel feed pipe and the fuel return pipe at the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
14. Disconnect the electrical connector from the fuel tank module.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Cap the open fuel and EVAP pipes on the vehicle in order to prevent possible fuel system contamination.
18. Remove the EVAP pipe from the roll over valves and the retainer clips.
19. Remove the fuel tank module from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
20. Remove the fuel fill hose from the fuel tank.

1. Install the fuel tank into the fuel tank shield (3)..
2. Remove the caps from the fuel and EVAP pipes.
3. Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
4. Install the fuel tank module to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
5. Connect the EVAP pipe to the roll-over valves and the retainer clips.
6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the electrical connector to the fuel tank module.
9. Connect the fuel feed pipe and the fuel return pipe to the fuel tank module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
10. Raise the tank fully.
11. Install the fuel tank straps (2).
12. Install the new attaching bolts (1) to the fuel tank straps. Tighten the fuel tank strap attaching bolts to 20.5 N.m (15 lb ft).
13. Connect the rear EVAP pipe (1) to the EVAP canister.
14. Connect the fuel fill vent hose (2) to the fill pipe.
15. Connect the fuel fill hose (1) to the fuel fill pipe and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
16. Lower the vehicle.
17. Refill the fuel tank.
18. Tighten the fuel filler cap.
19. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition . Inspect for fuel leaks.

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Clean all the fuel pipe connections and the surrounding areas before disconnecting the fuel pipes in order to avoid possible contamination of the fuel system.
5. Loosen the fuel fill hose clamp.
6. Disconnect the fuel fill hose (1) from the filler tube.
7. Disconnect the fuel fill vent hose (2) from the filler tube.
8. Disconnect the rear fuel return pipe at the chassis fuel return pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
9. Disconnect the rear fuel feed pipe at the chassis fuel feed pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
10. With the aid of an assistant, support the fuel tank.
11. Remove and discard the attaching bolts (1) from the fuel tank strap .
12. Remove the fuel tank straps (2).
13. Carefully lower the fuel tank.
14. Disconnect the fuel tank module and the fuel pump electrical connectors.
15. Remove the fuel tank.
16. Place the fuel tank in a suitable work area.
17. Remove the fuel tank module (1) and the fuel pipes from the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
18. Remove the evaporative emission (EVAP) hoses from the fuel tank.
19. On models with EVAP canister mounted to fuel tank, remove two tiedown straps from the (EVAP) canister (2) then remove the canister from the fuel tank. Discard tiedown straps.
20. On all models, remove the fuel fill hose from the fuel tank.
21. Remove the fuel tank from the fuel tank shield (3).

1. Install the fuel tank into the fuel tank shield (3).
2. Install the fuel fill hose to the fuel tank and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
3. On models with EVAP canister mounted to fuel tank, place the (EVAP) canister in position on the (EVAP) canister bracket, then install two new tiedown straps.
4. On all models, install the (EVAP) hoses to the fuel tank.
5. Install the fuel tank module (1) and the fuel pipes to the fuel tank. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
6. With the aid of an assistant, position and support the fuel tank.
7. Raise the fuel tank slightly.
8. Connect the electrical connectors to the fuel tank module and fuel pump.
9. Raise the tank fully.
10. Install the fuel tank straps (2).
11. Install the new attaching bolts (1) to the fuel tank strap and tighten the bolts to 20.5 N.m (15 lb ft).
12. Connect the chassis fuel feed pipe to the rear fuel feed pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
13. Connect the rear fuel return pipe to the chassis fuel return pipe. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
14. Connect the fuel fill vent hose (2) to the filler tube.
15. Connect the fuel fill hose (1) to the fuel tank and tighten the fuel fill hose clamp to 2.75 N.m (24 lb in).
16. Lower the vehicle.
17. Refill the fuel tank.
18. Tighten the fuel filler cap.
19. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

Scheme 53

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Remove the fuel pressure sensor (1).

1. Install the fuel pressure sensor (1).
2. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Scheme 54

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Remove the fuel pressure sensor (1).

1. Install the fuel pressure sensor (1).
2. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Fuel Tank Fuel Pump Module Replacement

Special Tools

J 45722 Fuel Sender Lock Nut Wrench

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) , «Fuel Tank Draining (With Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without Flex Fuel)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Use the J 45722 Fuel Sender Lock Nut Wrench and a long breaker-bar in order to unlock the fuel sender lock ring.
6. Remove the fuel sender assembly and the seal. Discard the seal.
7. Clean the fuel sender sealing surfaces.
8. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
9. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
10. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the new seal on the fuel tank.
2. Install the fuel sender assembly into the fuel tank.
3. Use the J 45722 Fuel Sender Lock Nut Wrench in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
4. Install the fuel tank. Refer to «Fuel Tank Replacement (Cutaway Van Rear Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Cutaway Van Side Tank)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Fuel Tank Replacement (Passenger/Cargo)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Refill the fuel tank.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition . Inspect for fuel leaks.

1. Remove the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .
2. Remove the two wire fuel level sensor connectors from the fuel sender assembly.
3. Using one of two pocket screwdrivers, pull the front retaining tab away from the front of the fuel level sensor while with the second pocket screwdriver push the fuel level sensor away and down from the fuel sender assembly.
4. Remove the fuel level sensor from the fuel sender assembly.

1. Install the fuel level sensor (1).
2. Connect the electrical connector to the fuel tank sender.
3. Install the fuel tank module. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-tank-fuel-pump-module-replacement) .

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
5. Remove the fuel feed and return pipes (4) from the fuel sender (2).

1. Install the fuel feed and return pipes (4) to the fuel sender (2).
2. Install the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
3. Lower the vehicle.
4. Refill the fuel tank.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.
7. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.

1. Disconnect the negative battery cable.
2. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
3. Remove the fuel filler cap.
4. Drain the fuel below the level of the fuel tank fill hose. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-without-l59) .
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
6. Loosen the fuel fill hose clamps (2, 3).
7. Remove the fuel fill hose (6).
8. Cap the open end of the fuel tank.

1. Uncap the fuel tank.
2. Install the fuel fill hose (6) and tighten the fuel fill hose clamps (2, 3) to 2.75 N.m (24 lb in).
3. Lower the vehicle.
4. Refill the fuel tank.
5. Install the fuel filler cap.
6. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
5. Remove the fuel feed and return pipes (6) from the fuel sender (1), the fuel filter, and the retaining clips.

1. Install the fuel feed and return pipes (6) to the fuel sender (1), the fuel filter, and the retaining clips.
2. Install the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
3. Lower the vehicle.
4. Refill the fuel tank.
5. Tighten the fuel filler cap.
6. Connect the negative battery cable.
7. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition . Inspect for fuel leaks.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-without-l59) .
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
5. Disconnect the fuel feed pipe at the fuel filter.
6. Disconnect the chassis fuel return pipe at the rear fuel return pipe.
7. Disconnect the chassis fuel feed and return pipes at the rear fuel feed and return pipes.
8. Remove the fuel pipe retaining clips.
9. Remove the fuel feed and return pipes.

1. Install the fuel feed and return pipes and the fuel pipe retaining clips (2) to the frame rail (1) and tighten the bolts to 12 N.m (106 lb in).
2. Connect the chassis fuel feed and return pipes to the rear fuel feed and return pipes (2).
3. Connect the chassis fuel return pipe to the rear fuel return pipe.
4. Connect the fuel feed pipe to the fuel filter.
5. Lower the vehicle.
6. Refill the fuel tank.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition switch. Inspect for fuel leaks.
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Drain the fuel tank. Refer to «Fuel Tank Draining (L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-l59) , «Fuel Tank Draining (Without L59)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-tank-draining-without-l59) .
4. Remove the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
5. Disconnect the fuel feed pipe at the fuel filter.
6. Disconnect the chassis fuel return pipe at the rear fuel return pipe.
7. Remove the fuel pipe retaining clips.
8. Remove the fuel feed and return pipes.

1. Install the fuel feed and return pipes and the fuel pipe retaining clips (1) and tighten the bolts to 12 N.m (106 lb in).
2. Connect the chassis fuel return pipe to the rear fuel return pipe.
3. Connect the fuel feed pipe to the fuel filter.
4. Install the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
5. Lower the vehicle.
6. Refill the fuel tank.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Disconnect the fuel feed and evaporative emission (EVAP) pipes from the engine compartment fuel pipes.
4. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor (2).
5. Remove the chassis wiring harness clip (3) from the fuel pipe.
6. Remove the fuel pipes from the bellhousing stud retainer clip.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
8. Disconnect the fuel feed pipe at the fuel tank.
9. Disconnect the chassis EVAP pipe from the fuel tank.
10. Remove the fuel pipe retaining clips. Note the location of the retaining clips for installation.
11. Remove the fuel feed and EVAP pipes.

1. Position the fuel feed and EVAP pipes in the vehicle.
2. Install the fuel pipe retaining clips and tighten the clips to 12 N.m (106 lb in).
3. Connect the chassis EVAP pipe to the fuel tank EVAP pipe.
4. Connect the fuel feed pipe to the fuel tank pipe.
5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor (2).
6. Install the chassis wiring harness clip (3) to the fuel pipe.
7. Lower the vehicle.
8. Install the fuel feed and EVAP pipes to the engine compartment fuel pipes.
9. Install the fuel pipes to the retainer clip and tighten the nut to 28 N.m (21 lb ft).
10. Tighten the fuel filler cap.
11. Connect the negative battery cable. «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
12. Inspect for leaks: Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
13. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor (2).
3. Remove the chassis wirng harness clip (3) from the fuel pipe.
4. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out.
5. Remove the fuel pressure sensor from the fuel line.
6. Remove and discard the fuel pressure sensor O-ring seal.

1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil.
2. Install the NEW fuel pressure sensor O-ring seal onto the fuel line fitting.
3. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out.
4. Install the fuel pressure sensor to the fuel line and tighten the sensor to 15 N.m (11 lb ft).
5. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor (2).
6. Install the chassis wiring harness clip (3) to the fuel pipe.
7. Lower the vehicle.
8. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Fuel Tank Cleaning

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the fuel tank module.
3. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump.
4. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
5. Flush the fuel tank with hot water.
6. Pour the water out of the fuel tank module opening. Rock the tank to be sure that removal of the water from the tank is complete.
7. Remove the fuel rail assembly. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
8. Drain the fuel from the fuel rail. It will be necessary to remove the fuel injectors from the fuel rail to properly clear all debris from the fuel rail and fuel injectors. Use light shop air to remove any debris from the fuel rail and injectors.
9. Replace the fuel injector O-rings.
10. Use light shop air in the opposite direction of the fuel flow in order to remove any debris from the fuel lines. Catch any fuel from the fuel lines with an approved gasoline container.
11. Install the injectors to the fuel rail.
12. Install the fuel rail assembly onto the engine. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
13. Install the fuel tank module.
14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
15. Purge the fuel tank module. Disconnect the fuel feed line from the fuel tank. Connect a length of hose to the fuel feed pipe. Insert the other end of the hose into an empty 3.8 liter (1 gallon) approved gasoline container. Add 23 liters (6 gallons) of clean fuel into the fuel tank. Turn on the fuel pump using the scan tool until 2 liters (1/2 gallon) of fuel flows into the fuel container.
16. Inspect for leaks: Turn the ignition switch ON for 2 seconds. Turn the ignition switch OFF for 10 seconds. Turn the ignition switch ON. Inspect for fuel leaks.

Note. An 8-digit identification number is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Remove the engine wiring harness bracket nut (1).
4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid.
5. Disconnect the engine wiring harness electrical connector (3) from the generator.
6. Disconnect the engine wiring harness electrical connector (4) from the manifold absolute pressure (MAP) sensor.
7. Remove the connector position assurance (CPA) retainer (2).
8. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector.
9. Disconnect the engine wiring harness electrical connectors (3) from the fuel injectors, perform the following: Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the CPA retainer on the connector up 1 click. Push the tab on the connector in. Disconnect the fuel injector electrical connector.
10. Remove the CPA retainer (2).
11. Disconnect the engine wiring harness electrical connector (1) from the ignition coil main electrical connector.
12. Disconnect the engine wiring harness electrical connector (3) from the electronic throttle control.
13. Disconnect the engine wiring harness electrical connectors (7) from the fuel injectors, perform the following: Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the CPA retainer on the connector up 1 click. Push the tab on the connector in. Disconnect the fuel injector electrical connector.
14. Remove the engine wiring harness clip (4) from the generator battery jumper cable.
15. Remove the engine wiring harness clip (6) from the ignition coil bracket stud.
16. Remove the negative battery cable stud (1) from the right cylinder head.
17. Remove the negative battery cable terminal (2) and engine wiring harness ground terminal (3) from the cylinder head.
18. Remove the engine wiring harness clip bolt (3) from the generator bracket.
19. Gather the branches of the engine wiring harness and reposition the aside.
20. Remove the positive crankcase ventilation (PCV) hose.
21. Disconnect the chassis fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__metal-collar-quick-connect-fitting-service) .
22. Disconnect the EVAP tube quick connect fitting at the intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
23. Disconnect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
24. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail.
25. Remove the EVAP tube and purge solenoid.
26. Remove the fuel rail bolts.
27. Remove the fuel rail assembly.
28. Remove the fuel injector retainers (1).
29. Remove the fuel injectors (3) from the fuel rail.
30. Remove and discard the fuel injector upper and lower O-ring seals (2 and 4).

1. Lubricate the NEW fuel injector O-ring seals with clean engine oil.
2. Install the NEW fuel injector upper and lower O-ring seals (2 and 4) onto the injectors.
3. Install the fuel injectors (3) into the fuel rails.
4. Install the fuel injector retainers (1).
5. Ensure the fuel injector lower O-ring seals are adequately lubricated, if not lubricate the fuel injector lower O-ring seals with clean engine oil.
6. Position the fuel rail onto the intake manifold.
7. Firmly push down on both the centers of the left and right fuel rails, until the rails are fully seated against the intake manifold.
8. Install the fuel rail bolts. Tighten Tighten the bolts to 10 N.m (89 lb in).
9. Install the EVAP tube and purge solenoid.
10. Install the EVAP canister purge solenoid to the fuel rail bracket and engage the retainer.
11. Connect the chassis EVAP tube quick connect fitting at the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
12. Connect the EVAP tube quick connect fitting at the intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
13. Connect the chassis fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__metal-collar-quick-connect-fitting-service) .
14. Install the PCV hose.
15. Gather the branches of the engine wiring harness and position over the top of the engine.
16. Position the engine wiring harness clip to the generator bracket and install the clip bolt (3). Tighten Tighten the bolt to 9 N.m (80 lb in).
17. Position the negative battery cable terminal (2) and engine wiring harness ground terminal (3) to the right cylinder head.
18. Install the negative battery cable stud (1) to the cylinder head. Tighten Tighten the stud to 25 N.m (18 lb ft).
19. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector.
20. Install the CPA retainer (2).
21. Connect the engine wiring harness electrical connector (3) to the electronic throttle control.
22. Connect the engine wiring harness electrical connectors (7) to the fuel injectors, perform the following: Ensure that the CPA retainer is pulled out 1 click. Connect the electrical connectors to their corresponding injectors. Push the CPA retainer in 1 click. Ensure that the connector is secured.
23. Install the engine wiring harness clip (4) to the generator battery jumper cable.
24. Install the engine wiring harness clip (6) to the ignition coil bracket stud.
25. Connect the engine wiring harness electrical connector (1) to the ignition coil main electrical connector.
26. Install the CPA retainer (2).
27. Connect the engine wiring harness electrical connectors (3) to the fuel injectors, perform the following: Ensure that the CPA retainer is pulled out 1 click. Connect the electrical connectors to their corresponding injectors. Push the CPA retainer in 1 click. Ensure that the connector is secured.
28. Connect the engine wiring harness electrical connector (4) to the MAP sensor.
29. Connect the engine wiring harness electrical connector (3) to the generator.
30. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid.
31. Install the engine wiring harness bracket nut (1). Tighten Tighten the nut to 5 N.m (44 lb in).
32. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
33. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for leaks.
34. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Scheme 55

Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (LPG 3 Tank)

Scheme 56

Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (LPG 3 Tank)

Note. The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly, that includes both the left and right rail assemblies and the crossover pipe rail.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-ch-48027) , «Fuel Pressure Relief (Without CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__fuel-pressure-relief-without-ch-48027) .
3. Disconnect the fuel feed (1) and the fuel return (2) pipes from the fuel rail.
4. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
5. Remove the fuel return pipe (1).
6. Remove and discard the fuel return pipe O-ring (6).
7. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25).
8. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
9. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
10. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15).
11. Remove and discard the crossover fuel pipe O-rings (7, 20).

1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). CAUTION: Refer to «Fastener Caution»(/chevrolet/express-h1500/2013-2013/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) . NOTE: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22).
5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
7. Install the fuel return pipe (1).
8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3). NOTE: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4). Tighten the crossover fuel pipe retainer clip attaching screws to 3.8 N.m (34 lb in). Tighten the fuel return pipe attaching screw to 5 N.m (44 lb in)
10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
11. Connect the fuel return (2) and fuel feed (1) pipes to the fuel rail.
12. Tighten the fuel fill cap.
13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
14. Use the following procedure in order to inspect for leaks: Turn ON the ignition, with the engine OFF, for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
15. Install the fuel pressure connection cap.

Note. The Denso fuel injectors that are installed in the 5.3L (L59) E85 application will not have O-rings and retaining clips serviced separately. Therefore, the fuel injectors will be replaced whenever an O-ring or clips needs to be replaced. The engine oil may be contaminated with fuel if the fuel injectors are leaking.

Scheme 57

1. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Remove the fuel injector retainer clip (19).
3. Remove the fuel injector (17).
4. Discard the injector retainer clip (1).
5. Remove and discard the fuel injector O-ring seals (2, 4) from the injector.

Note. When ordering new fuel injectors, you must order the correct injector for the application being serviced.

1. The fuel injector (1) is stamped with a part number identification (2). A four-digit build date code (3), which indicates the month (4), day (5), year (6), and the shift (7) that built the fuel injector.
2. Lubricate the NEW fuel injector O-ring seals (2, 4) with clean engine oil.
3. Install the NEW injector O-ring seals onto the fuel injector.
4. Install a NEW retainer clip (1) onto the fuel injector.
5. Install the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks onto a flange on the fuel rail injector socket.
6. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Scheme 58

Fuel Injector Replacement (LPG 3 Tank)

Fuel Injector Cleaning

Special Tools

1. J 35800-A Fuel Injector Cleaner
2. J 37287 Fuel Line Shut-Off Adapters
3. J 42873-1 3/8 Fuel Line Shut-Off Valve
4. J 42873-2 5/16 Return Pipe Shut-Off Valve
5. J 42964-1 3/8 Fuel Pipe Shut-Off Valve
6. J 42964-2 5/16 Fuel Pipe Shut-Off Valve

Note. Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced.

1. Obtain J 35800-A fuel injector cleaner (2).
2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A fuel injector cleaner , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline.
3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A fuel injector cleaner , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool.
5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped.
6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 fuel line shut-off adapters , or J 42964-1 3/8 fuel pipe shut-off valve , and J 42964-2 5/16 fuel pipe shut-off valve or J 42873-1 3/8 fuel line shut-off valve , and J 42873-2 5/16 return pipe shut-off valve as appropriate for the fuel system.
7. Connect the J 35800-A fuel injector cleaner to the vehicle fuel rail.
8. Pressurize the J 35800-A fuel injector cleaner to 510 kPa (75 psi).
9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes.
10. Turn the ignition to the OFF position.
11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12.
12. Disconnect the J 35800-A fuel injector cleaner from the fuel rail.
13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
14. Remove the J 37287 fuel line shut-off adapters , or J 42964-1 3/8 fuel pipe shut-off valve and J 42964-2 5/16 fuel pipe shut-off valve , or J 42873-1 3/8 fuel line shut-off valve J 42873-1 3/8 fuel line shut-off valve and and reconnect the vehicle fuel feed and return lines.
15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines.
16. Pour the entire contents of GM Fuel System Treatment Plus, GM P/N 88861011 (Canadian P/N 88861012) into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel.
17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure.
18. Road test the vehicle to verify that the customer concern has been corrected.

Scheme 59

1. IMPORTANT: Clean all evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting, in order to avoid possible EVAP system contamination. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Disconnect the EVAP line quick connect fitting from the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Disconnect the engine wiring harness electrical connector (2) from the EVAP canister purge solenoid.
4. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister purge solenoid.
5. Disengage the retainer securing the EVAP canister purge solenoid to the fuel rail.
6. Remove the EVAP canister purge solenoid.

1. Install the EVAP canister purge solenoid.
2. Install the EVAP canister purge solenoid to the fuel rail and engage the retainer.
3. Connect the engine wiring harness electrical connector (2) to the EVAP canister purge solenoid.
4. Connect the chassis EVAP line quick connect fitting to the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Connect the EVAP line quick connect fitting to the EVAP canister purge solenoid.
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Scheme 60

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the electrical connector from the EVAP vent valve .
3. Disconnect the canister vent hose.
4. Bend back the tang on the bracket.
5. Slide the EVAP vent valve off the bracket.

1. Slide the EVAP vent valve onto the bracket.
2. Connect the canister vent hose.
3. Connect the electrical connector to the EVAP vent valve .
4. Lower the vehicle.

1. Clean the pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the EVAP system.
2. Disconnect the engine compartment EVAP pipe at the EVAP canister purge valve.
3. Disconnect the engine compartment EVAP pipe (1) at the chassis EVAP pipe (2).
4. Remove the EVAP pipe from the engine.
5. Cap the EVAP canister purge valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination.

1. Remove the caps from the EVAP canister purge valve and the chassis EVAP pipe.
2. Install the EVAP pipe on the engine.
3. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2).
4. Connect the engine compartment EVAP pipe at the EVAP canister purge valve.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .
2. Disconnect the rear EVAP vapor pipe (1) from the fuel sender (2), the fuel tank roll over valve (3), and the fuel tank clips (6).
3. Remove the EVAP vapor pipe from the fuel tank.
4. Cap the fuel sender EVAP pipe and the fuel tank roll over valve.

1. Remove the caps from the fuel sender EVAP pipe and the fuel tank roll over valve.
2. Position the EVAP vapor pipe on the fuel tank.
3. Connect the EVAP vapor pipe (1) to the fuel sender (2), the fuel tank roll over valve (3), and the fuel tank clips (6).
4. Install the fuel tank. Refer to «Fuel Tank Replacement (E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) , «Fuel Tank Replacement (Without E26)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-43-lu3-repair-instructions) .

Note. When replacing the evaporative emission (EVAP) pipe, always replace the pipe with original equipment or parts that meet the GM specifications for this part. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Clean all the EVAP pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the EVAP system.
3. Disconnect the engine compartment EVAP pipe (1) from the chassis EVAP pipe (2).
4. Cap the engine compartment EVAP pipe.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
6. Remove the EVAP pipe from the bellhousing stud clip.
7. Remove the EVAP pipe from the transmission bracket clip.
8. Remove the EVAP pipe from the transfer case bracket clip, AWD drive only.
9. Disconnect the rear EVAP purge pipe (3) from the chassis EVAP purge pipe (2).
10. Cap the rear EVAP purge pipe (3).
11. Note the position of the EVAP pipe for aid in installation.
12. Remove the EVAP pipe from the retaining clips (1).
13. Remove the EVAP pipe.

1. Install the EVAP pipe into the retaining clips (1).
2. Remove the cap from the rear EVAP pipe.
3. Connect the rear EVAP purge pipe (3) to the chassis EVAP purge pipe (2).
4. Install the EVAP pipe into the transfer case bracket clip, AWD drive only.
5. Install the EVAP pipe into the transmission bracket clip.
6. Install the EVAP pipe into the bellhousing stud clip (3).
7. Lower the vehicle.
8. Remove the cap from the engine compartment EVAP pipe.
9. Connect the engine compartment EVAP pipe (1) to the chassis EVAP pipe (2).
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the vent hose from the canister.
3. Disconnect the chassis EVAP purge pipe from the EVAP canister.
4. Disconnect the fuel tank EVAP pipe from the canister.
5. Remove the EVAP canister from the EVAP canister bracket.

1. Install the EVAP canister to the EVAP canister bracket.
2. Connect the fuel tank EVAP pipe to the canister.
3. Connect the chassis EVAP purge pipe to the EVAP canister.
4. Connect the vent hose to the canister.
5. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the vent hose from the canister.
3. Disconnect the chassis EVAP purge pipe from the EVAP canister.
4. Disconnect the fuel tank EVAP pipe from the canister.
5. Remove the EVAP canister from the EVAP Canister bracket.

1. Connect the fuel tank EVAP pipe to the canister.
2. Connect the chassis EVAP purge pipe to the EVAP canister.
3. Connect the vent hose to the canister.
4. Install the EVAP canister to the EVAP Canister bracket.
5. Install the EVAP canister bracket bolt and tighten to 12 N.m (106 lb in).
6. Lower the vehicle.

Scheme 61

Evaporative Emission System Vacuum Leak Detection Pump Replacement (LPG 3 Tank)

Evaporative Emission System Cleaning

Special Tools

J 41413 EVAP Pressure/Purge Diagnostic Station

Inspection Procedure

Note. Do not perform this procedure unless instructed by an evaporative emission (EVAP) diagnostic.

1. Turn OFF the ignition.
2. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Lightly tap the EVAP canister purge solenoid valve on a clean hard surface.
4. Inspect for carbon particles exiting either of the vacuum ports. If no carbon particles are found reinstall the EVAP canister purge solenoid valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) . If carbon particles are found during the inspection procedure, replace the EVAP canister purge solenoid valve and continue with the EVAP cleaning procedure. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) . If you were instructed to replace the EVAP canister purge solenoid valve, and no carbon particles are found, return to the EVAP diagnostic procedure. Do not perform the EVAP cleaning procedure.

EVAP Cleaning Procedure

1. Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement (Passenger/Cargo Van)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Evaporative Emission Canister Replacement (Cutaway Van)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Turn OFF the main valve on the J 41413 EVAP Pressure/Purge Diagnostic Station.
3. Disconnect the hose from the diagnostic station pressure regulator.
4. Using a section of vacuum hose, connect one end to the diagnostic station pressure regulator.
5. Connect the other end of the vacuum hose to the canister side of the purge pipe.
6. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
7. If the nitrogen does not dislodge the carbon particles, replace the purge pipe. Refer to «Evaporative Emission System Hose/Pipe Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
8. Return the EVAP pressure/purge diagnostic station to the stations original condition.
9. Install a new EVAP canister. Refer to «Evaporative Emission Canister Replacement (Passenger/Cargo Van)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , «Evaporative Emission Canister Replacement (Cutaway Van)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
10. Connect all previously disconnected EVAP pipe connectors.
11. Lower the vehicle.
12. Continue with the published service manual diagnostic DTC procedure.

Scheme 62

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the spark plug wires at the ignition coils.
3. Disconnect the ignition coil harness connector.
4. Remove the ignition coil mounting bolts.
5. Remove the ignition coil.

1. Install the ignition coil to the bracket.
2. Install the ignition coil mounting bolts and tighten to 8 N.m (71 lb in).
3. Connect the ignition coil harness connector.
4. Connect the spark plug wires at the ignition coils.
5. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions

1. Correct routing of the spark plug wires-Incorrect routing may cause cross-firing.
2. Any signs of cracks or splits in the wires
3. Inspect each boot for the following conditions: Tearing Piercing Arcing Carbon tracking Corroded terminal

If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
2. Disconnect the spark plug wire at each spark plug. Twist each spark plug wire 1/2 turn. Pull only on the boot in order to remove the wire from each spark plug.
3. Disconnect the spark plug wire from the ignition coil. Twist each spark plug boot 1/2 turn. Pull only on the boot in order to remove the wires from the ignition coil.

Spark Plug Wire Length V8

1. The Melco® (square design) uses a spark plug wire (1) that is 145 mm (5.70 in) length cable seal to cable seal.
2. The Delphi® (round design) uses a spark plug wire (2) that is 110 mm (4.30 in) length cable seal to cable seal.
3. There are 2 different manufacturers for the ignition coils. the Melco® (1) (square design), and the Delphi® (2) (round design). These 2 coils use 2 different spark plug wire, and mounting brackets.
4. Melco® (square design) coil mounting bracket (1).
5. Delphi® (round design) coil mounting bracket (2).

1. Install the spark plug wires at the ignition coil.
2. Inspect the inside of the ignition coil rubber boot for a thin, even coat of grease. If there is no grease present or additional grease is necessary, complete the following procedure: Apply a thin coating of dielectric grease evenly to the inside of the ignition coil rubber boot, up to a depth of 15 mm from the end of the boot. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/express-h1500/2013-2013/remont/mechanical/#engine-mechanical-48l-l20-53l-lmf-or-60l-l96-lc8-specifications__adhesives-fluids-lubricants-and-sealers) . Remove any excess grease from around the end of the boot, and ensure there is not an excessive amount within the boot.
3. Install the spark plug wire to each spark plug.
4. Inspect the wires for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
5. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .

Spark Plug Usage

1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to the Electronic Parts Catalog.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

1. Inspect the terminal post (1) for damage: Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
4. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-specifications__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-specifications__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. Inspect for excessive fouling.
5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.

1. Remove the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Loosen each spark plug 1 or 2 turns.
3. Brush or air blast away any dirt from around the spark plugs.
4. Remove the spark plugs one at a time. Place each plug in a tray marked with the corresponding cylinder numbers.

1. Inspect each spark plug gap. Adjust each plug as needed. Refer to «Ignition System Specifications»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-specifications__ignition-system-specifications) .
2. Hand start the spark plugs in the corresponding cylinders.
3. Tighten the spark plugs for used heads to 15 N.m (11 lb ft). Tighten the spark plugs for new aluminum heads to 20 N.m (15 lb ft). Tighten the spark plugs for new iron heads to 30 N.m (22 lb ft).
4. Install the spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Note. Perform the Crankshaft Position System Variation Learn when the CKP sensor is removed or replaced.

1. Disconnect the negative battery cable.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the starter. Refer to «Starter Replacement (V8)»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Disconnect the crankshaft position (CKP) sensor electrical connector.
5. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
6. Remove the CKP sensor retaining fastener.
7. Remove the CKP sensor.

1. Install the CKP sensor.
2. Install the CKP sensor retaining fastener and tighten to 25 N.m (18 lb ft).
3. Connect the CKP sensor electrical connector.
4. Install the starter. Refer to «Starter Replacement (V8)»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Lower the vehicle.
6. Connect the negative battery cable.
7. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__crankshaft-position-system-variation-learn) .

Scheme 63

1. Remove the water pump. Refer to «Water Pump Replacement (V8)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Water Pump Replacement (LMF/LY2)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Disconnect the engine wiring harness electrical connector (1) from the CMP sensor wire harness.
4. Remove the 3 CMP sensor wire harness bolts (738).
5. Disconnect the CMP sensor wire harness electrical connectors from the CMP sensor and the CMP actuator magnet.
6. Remove the CMP sensor wire harness (737).
7. Remove the CMP sensor (703) and O-ring seal (704).

1. Inspect the CMP O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be used again.
2. Lubricate the O-ring seal with clean engine oil.
3. Install the O-ring seal (704) onto the sensor.
4. Instal the CMP sensor (703) to the front cover.
5. Install the CMP sensor wire harness (737).
6. Connect the CMP sensor wire harness electrical connectors to the CMP sensor and the CMP actuator magnet.
7. Install the 3 CMP sensor wire harness bolts (738). Tighten Tighten the bolts to 12 N.m (106 lb in).
8. Connect the engine wiring harness electrical connector (1) to the CMP sensor wire harness.
9. Lower the vehicle.
10. Install the water pump. Refer to «Water Pump Replacement (V8)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Water Pump Replacement (LMF/LY2)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Lift and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the engine wiring harness electrical connector (4) from knock sensor.
3. Remove the knock sensor bolt (739) and knock sensor (718).

1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 N.m (18 lb ft)
2. Connect the engine wiring harness electrical connector (4) to knock sensor.
3. Lower the vehicle.

1. Lift and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Disconnect the engine wiring harness electrical connector (2) from knock sensor.
3. Remove the knock sensor bolt (739) and knock sensor (718).

1. Position the knock sensor (718) to the engine block and install the knock sensor bolt (739). Tighten the bolt to 25 N.m (18 lb ft)
2. Connect the engine wiring harness electrical connector (2) to knock sensor.
3. Lower the vehicle.

Scheme 64

Air Cleaner Element Replacement

Scheme 65

Air Cleaner Assembly Replacement

Scheme 66

Air Cleaner Resonator Outlet Duct Replacement

Compressed Natural Gas Fuel Pressure Relief (With CH-48027)

Special Tools

CH-48027 Digital Pressure Gauge

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Remove the aft and cargo tank covers. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , and «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Close all manual shut-off valves to service the tanks.
3. Remove the engine cover, if required. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
4. Attempt to start the vehicle. The engine may start for a second or two.
5. The high pressure side of the high pressure regulator will contain approximately 200 PSIG.
6. Open the fuel line connections slowly to relieve the residual pressure.
7. If servicing the low side pressure of the HPR, use the CH-48027 gauge to relieve the remaining pressure.

Compressed Natural Gas Tank Venting

Special Tools

CH-48027 Digital Pressure Gauge

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the fuel tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Carefully remove the cargo tank valve plastic cover. Do not damage or discard this cover. Replace if damaged
4. If the fuel system is near empty, you may close the unaffected tank manual valves and run the vehicle until the tank is empty.
5. If not, close the unaffected tank manual valves and perform the following: Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) . Connect the CH-48027 gauge to the fuel rail. Route the pressure relief hose into an approved vent stack attached to an area outside the building.
6. Using a fused jumper wire, jumper the fuel pump relay terminals 30 to 87 to begin the venting process. The CNG fuel tank is completely vented when all of the following conditions have been met: Venting gas flow is no longer audible from the vent stack. If ambient temperature is lower than 7°C (45°F), warm the fuel tank and vent assembly by placing in a warm environment or spraying with warm water.
7. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Loosen the high pressure fuel line fitting at the CNG fuel tank to be removed for venting several turns to allow residual system pressure to be released. Completely disconnect fitting when fuel line can be moved away from mating fitting by hand.
9. Remove the CNG fuel tank from the vehicle. Refer to «Compressed Natural Gas Tank Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-tank-replacement) , , or «Compressed Natural Gas Tank Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

Scheme 67

LPG Fuel Tank Drain Valve Replacement (Passenger Side 3 Tank)

Scheme 68

LPG Fuel Tank Drain Valve Replacement (Drivers Side 3 Tank)

LPG Tank Drain and Evacuation

Special Tools

1. CH-50934 Hose Assembly, LPG Tank Transfer
2. CH-50935 Flare Stack, LPG Vapor Burn-Off

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

The safest way to empty a LPG tank is to

1. Use the fuel in the tank.
2. Transfer the fuel to an empty tank.
3. Burn the fuel through a flare stack.

It is never recommended to release more than minimal amounts of LPG to the atmosphere.

Transferring Fuel from One Tank to Another

1. Remove the vehicle fuel tank shield.
2. Disconnect the negative vehicle battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Be sure the LPG fuel tank drain valve (8) is closed on the vehicle's fuel tank (7), and that the drain valve and fill bleeder valve (spitter valve) on the receiving tank (2) are both closed. Remove the brass caps from the fuel tank drain valves on both tanks.
4. Connect CH-50934 Hose Assembly, LPG Tank Transfer (6) from the vehicle tank liquid service valve to a receiving tank liquid service valve.
5. Slowly open the fuel tank drain valves on both tanks.
6. Open the receiving tank fill bleeder valve.
7. The drain valve may be opened for more flow, but if the flow rate is exceeded, the excess flow protection could close.
8. The LPG fuel transfer hose contains a sight glass with a ball that indicates the fuel flow. When the tank being evacuated is empty of liquid or the flow of liquid has stopped, turn off all tank valves, and remove the LPG fuel transfer hose assembly.
9. Connect the flare stack hose to the fill bleeder valve of the tank being evacuated.
10. Open the fill bleeder valve of the tank being evacuated and light the flare stack to burn the remaining fuel in the tank.
11. If frost or ice appears on the bottom of the tank being evacuated, liquid fuel is in that area of the tank. The area of the tank with frost or ice may be sprayed with a water hose to help vaporize the fuel so that it may flow from the tank.
12. After the fuel tank service is complete, install the brass cap on the LPG fuel tank drain valve and bleeder valve.
13. Install the vehicle fuel tank shield.

Flaring Off (Burning) the Fuel From a Tank

1. Remove the vehicle fuel tank shield.
2. Disconnect the negative vehicle battery cable and the LPDM connector from the fuel pump flow control module.
3. Be sure the LPG fuel drain valve is closed and remove the brass cap from the valve.
4. Connect one end of the CH-50934 Hose Assembly, LPG Tank Transfer to the LPG fuel tank drain valve. Using an appropriate union, connect the other end of the fuel transfer hose to the hose of the CH-50935 Flare Stack, LPG Vapor Burn-Off.
5. Close the flare stack valve. Open the LPG fuel tank drain valve. Open the valve on the flare stack 1/4 turn, and light the flare stack.
6. If the flare stack is equipped with a valve, slowly open the valve until the flow rate and the burn rate are maximized.
7. If the flare stack flame goes out due to improper fuel mixture, wind or any reason, the drain valve must be closed immediately. Wait a few minutes for any accumulation of fuel vapor to dilute into the atmosphere before attempting to restart or relight the flare stack.
8. A technician trained in this procedure must attend the process at all times and cannot leave the area without closing off all valves and discontinuing the evacuation process.
9. When the level of the liquid fuel in the tank drops below the drain valve, the remaining liquid fuel in the tank must vaporize before it will flow from the tank. A frost or ice line on the tank indicates liquid fuel is in the tank and the burning process is faster than the liquid in the tank can vaporize. The area of the tank with frost or ice may be sprayed with a water hose to help vaporize the fuel so that it may more easily flow from the tank.
10. Close all valves to see if pressure builds up in the tank - this indicates some liquid fuel remains in the tank. Do not remove any valve, gauge or LPDM from the tank until it is completely empty of liquid and vapor fuel.
11. After the fuel tank service is complete, install the brass cap on the LPG fuel tank drain valve and bleeder valve.
12. Install the vehicle fuel tank shield.

LPG Fuel Line Draining

Special Tools

CH-50933 Gauge Assembly, Liquid Propane Gas (LPG)

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

Draining the Fuel Lines

1. Remove the vehicle fuel tank shield.
2. Disconnect the vehicle's negative battery terminal and the LPDM connector from the fuel pump flow control module.
3. Connect the CH-50933 Gauge Assembly, Liquid Propane Gas (LPG) to the Schrader Valve located at the LPDM on the mid-ship tank.
4. The Schrader Valve is connected to the liquid supply section of the system, but also accesses the fuel return section.
5. Open the valve on the gauge set, and allow the fuel lines to bleed out until the gauge reads zero.
6. Leave the gauge set hooked up and leave the valve open until the necessary service is complete.

LPG Fuel Line Draining (3 Tank Feed and Return)

Special Tools

CH-50933 Gauge Assembly, Liquid Propane Gas (LPG)

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Disconnect the vehicle's negative battery terminal. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Close the supply, return, and bypass valves.
3. Connect the CH-50933 Gauge Assembly, Liquid Propane Gas (LPG) to the Schrader Valve located on the rear of the left fuel rail.
4. The Schrader Valve is connected to the liquid supply section of the system, but also accesses the fuel return section.
5. Open the valve on the gauge set, and allow the fuel lines to bleed out until the gauge reads zero.
6. Leave the gauge set hooked up and leave the valve open until the necessary service is complete.

Venting Procedure

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the fuel tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Remove the clear plastic vent cover from the cargo tank valve. Do not discard. Replace if damaged.
4. Close all manual shut-off valves. The "Closed" position is achieved by rotating manual shut-off valve clockwise until seated.
5. Relieve the CNG fuel system pressure. Refer to «Compressed Natural Gas Fuel Pressure Relief (With CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-fuel-pressure-relief) .
6. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
7. Loosen the high pressure fuel line fitting at the CNG 1/4 turn valve several turns to allow residual system pressure to be released.
8. Completely disconnect both fuel line fittings from the 1/4 turn valve so as the fuel line can be moved away from the mating fitting by hand.
9. Remove the 1/4 turn valve locknut and remove the 1/4 turn valve handle.
10. Remove the 1/4 turn valve.

1. Install New 1/4 turn valve on HPR bracket using new locknut. Tighten to spec.
2. Install red handle and tighten allen set screw. Tighten to spec.
3. Connect 1/4 turn valve inlet and outlet fuel lines using New O-rings. Lubricate New O-rings with petroleum jelly or equivalent before installation.
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Install the fuel tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
6. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the fuel tank cover from the fuel tank to be serviced. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , or «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
3. Close the manual shut-off valve for the tank being serviced.
4. Disconnect the high pressure lock-off (HPL) solenoid electrical connector.
5. Remove the HPL solenoid coil retaining nut.
6. Remove the HPL solenoid coil.

1. Install the HPL solenoid coil onto the core tube.
2. Install the HPL solenoid coil retaining nut and tighten to 10 N.m (89 lb in).
3. Connect the HPL solenoid electrical connector.
4. Open ALL the manual shut-off valves.
5. Install the fuel tank cove to the serviced fuel tank. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , or «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
6. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .

LPG Tank Purge

Special Tools

CH-50935 Flare Stack, LPG Vapor Burn-Off

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Disconnect the negative battery cable.
2. Remove the vehicle fuel tank shield.
3. Remove the brass cap from the vehicle LPG fuel tank drain valve.
4. Open the vehicle LPG fuel tank drain valve to release any pressure build up and allow the tank to equalize to atmospheric pressure.
5. Connect a LPG vapor source to the LPG fuel tank drain (1). The LPG vapor source used may be a 20 # cylinder, such as used for a barbecue grill, with a hose containing an adjustable high pressure regulator (2).
6. Adjust the high pressure regulator to 103 kPa (15 PSI).
7. Slowly open the vapor service valve (1) on the LPG vapor source and allow the pressure to equalize to 103 kPa (15 PSI) in the tank. Close the valve.
8. Connect the CH-50935 Flare Stack, LPG Vapor Burn-Off to the vehicle's fuel tank fill bleeder valve (spitter valve).
9. Close the flare stack valve. Open the LPG fuel tank fill bleeder valve. Open the valve on the flare stack, and light the flare stack. Release all the pressure in the vehicle tank, and close the fill bleeder valve when the flame on the flare stack goes out.
10. In order to ensure that at least 95% of the air is removed, the fuel tank must be pressurized and bled down or depressurized several times. Usually 3 to 5 times is sufficient.
11. On the last purge with vapor, leave the tank pressurized and check the tank and valves for leaks with an approved leak detection fluid or electronic combustible gas detector. If any leaks are found, correct any leaks as necessary, and purge the tank again.
12. Fill the tank with 5 gallons of fuel before any electrical components are reconnected. This will insure there is no or very little air in the tank.
13. Check the tank and valves for leaks with an approved leak detection fluid or electronic combustible gas detector. If any leaks are found, correct any leaks as necessary, and purge the tank again.
14. After the fuel tank service is complete, install the brass cap on the LPG fuel tank drain valve and bleeder valve.
15. Install the vehicle fuel tank shield.

1. Raise and properly support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Vent both aft fuel tanks if replacing one using the «Compressed Natural Gas Tank Venting»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-tank-venting) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Close the manual tank valve(s).
5. Support tank assembly with aft axle tank cradle.
6. Remove the trailer hitch. Refer to «Trailer Hitch Platform Replacement»(/chevrolet/express-h1500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Disconnect the electrical connections.
8. Disconnect the fuel line fittings.
9. Remove the bracket support nuts and lower aft axle tank assembly.
10. Disconnect the aft tank fuel lines.
11. Remove the aft tank retaining straps.
12. Carefully remove the aft tanks from the vehicle.

1. The PRD and lines must be transferred to the new tank assembly before installation. Replace all O-rings with new seals and tighten fittings to 35 N.m (26 lb ft).
2. Raise the tank assembly up to the bolt locations.
3. Install the bracket support nuts. Tighten the mounting nuts to 79 N.m (60 lb ft).
4. Connect the fuel inlet line to the tank valve using a new O-ring. Lubricate the O-ring with petroleum jelly or equivalent. Tighten the fitting to 35 N.m (26 lb ft).
5. Connect the electrical connectors at the HPL.
6. Open the manual tank valve(s).
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Pressurize the CNG fuel system by cycling the ignition ON and OFF several times.
9. Start the engine and use a commercially available combustible gas detector in order to inspect for CNG fuel system leaks at each serviced fitting.
10. Install the trailer hitch. Refer to «Trailer Hitch Platform Replacement»(/chevrolet/express-h1500/2013-2013/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Install the fuel tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
12. Lower the vehicle

Compressed Natural Gas Tank Replacement - Cargo Tank

Special Tools

J-45529 Tank Removal Tool

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

1. Vent the cargo fuel tank. Refer to «Compressed Natural Gas Tank Venting»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-tank-venting) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Disconnect the fuel outlet line from the high pressure lock-off (HPL) solenoid.
4. Disconnect the HPL vent lines.
5. Disconnect the electrical connector at the high pressure lock-off solenoid.
6. Remove all of the tank strap retaining nuts and bolts.
7. Support the tank assembly with the J-45529 tool using an engine hoist.
8. Remove the tank from the vehicle.

1. Position the tank assembly in the vehicle.
2. Raise and lower the tank assembly onto the vehicle tank brackets.
3. Install the tank strap retaining nuts and bolts and tighten the mounting fasteners to 40 (30 lb ft).
4. Connect the fuel inlet line to the high pressure lock-off using a new O-ring. Lubricate the O-ring with petroleum jelly or equivalent. Tighten the fitting to 35 (26 lb ft).
5. Connect the HPL vent lines and tighten to 35 (26 lb ft).
6. Connect the electrical connector at the high pressure lock-off solenoid.
7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Open all tank manual valves.
9. Prime the CNG fuel system by cycling the ignition ON and OFF several times.
10. Start the engine and use a commercially available combustible gas detector in order to inspect for CNG fuel system leaks at each serviced fitting.
11. Install the vapor bag.
12. Install the fuel tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

1. Perform the fuel tank venting procedure. Refer to «Compressed Natural Gas Tank Venting»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-tank-venting) .
2. Close the manual tank valve.
3. Remove the tank shield brackets.
4. Disconnect the electrical connectors.
5. Remove the high pressure fuel supply line.
6. Support the tank on the tank cradle assembly and remove the 4 bracket bolts.
7. Lower the tank assembly.
8. Disassemble the PRD bracket and lines.
9. Remove the tank retaining straps.

1. Install the tank retaining straps and brackets. Make sure the straps are oriented properly and tighten to 40 N.m (30 lb ft).
2. If replacing the tank assembly, PRD connecting lines, brackets and devices must be transferred to the new tank. Replace all O-rings.
3. Support midship tank assembly on tank cradle assembly and raise.
4. Secure using the 4 tank assembly bracket bolts and tighten to 79 N.m (60 lb ft).
5. Install the high pressure fuel supply line.
6. Using New O-rings, lubricate the new O-rings with petroleum jelly or equivalent before installation.
7. Connect the electrical connectors.
8. Install the tank shield brackets and tighten the bolts to 60 N.m (52 lb ft).
9. Open the manual tank valves.
10. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.
11. Install ALL the fuel tank covers. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tank shield bolts only, while an assistant holds the shield in place.
3. Lower the shield from the vehicle.

1. Position the shield around the tank frame.
2. While an assistant holds the shield in place, loosely install the shield retaining bolts. Tighten the bolts to 20 N.m (14 lb ft).
3. Lower the vehicle.

1. Remove the top and front panel retaining bolts from the cargo fuel tank enclosure.
2. Remove the top and front panels from the cargo tank enclosure.

1. Reinstall the top and front cargo tank enclosure panels.
2. Tighten the bolts to 15 N.m (10 lb ft).

1. Rase and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tank shield bolts only, while an assistant holds the shield in place.
3. Lower the shield from the vehicle.

1. Position the shield around the tank frame.
2. While an assistant holds the shield in place, loosely install the shield retaining bolts.
3. Tighten the shield retaining bolts to 20 N.m (14 lb ft)
4. Lower the vehicle.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the fill line fitting from the fill valve.
3. Remove the fuel fill valve retaining bolts and reposition the pipe
4. Remove the 3 nuts retaining the fill valve plate.
5. Remove the fill valve and plate assembly.
6. Secure fill valve with a proper wrench and remove the fill valve jam nut.
7. Remove the fill valve from the mounting plate.

1. Install the fill valve into the mounting plate.
2. Install the fill valve jam nut and tighten to 35 N.m (26 lb ft).
3. Reinstall the fill valve plate assembly with bolt support plate and 3 retaining nuts. Tighten the nuts to 10 N.m (89 lb in).
4. Install the fill line fitting to the fill valve using a new O-ring. Lubricate the O-ring with petroleum jelly or equivalent before installation. Tighten the fill line fitting to 35 N.m (26 lb ft).
5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
6. Start the engine and use a commercially available combustible gas detector in order to inspect for CNG fuel system leaks at each serviced fitting.

1. Close ALL manual tank valves. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Relieve the compressed natural gas (CNG) fuel system pressure. Refer to «Compressed Natural Gas Fuel Pressure Relief (With CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-fuel-pressure-relief) .
3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
5. Loosen the high pressure fuel line fitting at the tank/fitting/valve several turns to allow residual system pressure to be released.
6. Completely disconnect fuel line from fittings when fuel line can be moved away from the mating fitting by hand.
7. Disconnect the hose fitting at the fuel line fitting and tank valve.
8. Remove the fuel line from the vehicle.

1. Connect the CNG fuel line to the fuel fittings and tighten using NEW O-rings. Lubricate the new O-rings with petroleum jelly or equivalent before installation. Tighten the fuel line fittings to 35 N.m (26 lb ft).
2. Open ALL manual tank valves.
3. Install ALL fuel tank covers. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
4. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.

1. Relieve the compressed natural gas (CNG) fuel system pressure. Refer to «Compressed Natural Gas Fuel Pressure Relief (With CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-fuel-pressure-relief) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Remove the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Disconnect the fuel line fittings at the tee.
6. Remove the fuel line tee from the vehicle.

1. Connect the CNG fuel lines to the tee fitting using New O-rings. Lubricate New O-rings with petroleum jelly or equivalent before installation. Tighten the fuel line fitting to 35 N.m (26 lb ft).
2. Open all manual shut-off valves to each fuel tanks.
3. Install ALL the tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
4. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
5. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.

1. Remove the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
2. Close the red 1/4 turn valve at the high pressure regulator (HPR).
3. Turn the key ON and run the vehicle until it stalls. Turn the key OFF.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
5. Loosen coalescing filter drain plug to relieve any residual pressure and check for presence of oil.
6. Remove coalescing filter housing to replace filter element.

1. Install the New filter element using new coalescing filter housing upper O-ring and new drain plug O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation. Tighten the coalescing filter housing to 7 N.m (5 lb ft). Tighten the drain plug to 7 N.m (5 lb ft).
2. Open 1/4 turn valve.
3. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.
4. Install the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .

1. Relieve the compressed natural gas (CNG) fuel system pressure. Refer to «Compressed Natural Gas Fuel Pressure Relief (With CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-fuel-pressure-relief) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Remove the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
5. Close the red 1/4 turn valve at the high pressure regulator (HPR).
6. Carefully loosen and disconnect the high pressure line to the HPR to relieve residual pressure.
7. Disconnect the low pressure line fitting at the HPR outlet.
8. Disconnect the electrical connections.
9. Remove the HPR assembly bracket nuts and washers.
10. Install coolant hose pinch-off tool to coolant lines and place a drain pan under the HPR assembly.
11. Mark and remove coolant lines.

1. Connect coolant lines to the original port locations on the HPR.
2. Install HPR bracket assembly and torque to spec.
3. Connect all electrical connections.
4. Connect Fuel lines and torque to spec. Tighten the HPR bracket nuts to 40 N.m (29.5 lb ft). Tighten the high pressure fuel line fittings to 35 N.m (26 lb ft). Connect the low pressure fuel line fitting to the HPR outlet fitting using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation. Tighten the low pressure fuel line tube nuts to 45 N.m (33 lb ft)
5. Open ALL the CNG tank valves.
6. Install ALL the fuel tank covers. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
7. Open 1/4 turn valve.
8. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
9. Add coolant if necessary. Refer to «Cooling System Draining and Filling (Static Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Vac N Fill)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling-vac) , «Cooling System Draining and Filling (Static Fill Diesel)»(/chevrolet/express-h1500/2013-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.

1. Relieve the compressed natural gas (CNG) fuel system pressure. Refer to «Compressed Natural Gas Fuel Pressure Relief (With CH-48027)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__compressed-natural-gas-fuel-pressure-relief) .
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
4. Disconnect the fill line fitting at the check valve and discard the O-ring.
5. Remove the check valve from the fitting and discard the O-ring.

1. Install the check valve to the fitting using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation. Tighten the check valve to 35 N.m (26 lb ft).
2. Connect the fill line fitting to the check valve using a NEW O-ring. Lubricate the new O-ring with petroleum jelly or equivalent before installation. Tighten the fuel line fitting to 35 N.m (26 lb ft).
3. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
4. open ALL the tank valves.
5. Install ALL the fuel tank covers. Refer to «Compressed Natural Gas Tank Cover Replacement - Aft Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , , «Compressed Natural Gas Tank Cover Replacement - Cargo Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) , and «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions) .
6. Start the vehicle and inspect for CNG fuel leaks at the serviced fittings with a commercially available combustible gas detector.

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions)
4. Remove the 3 electrical connectors from the FCM.
5. Remove the 2 FGCM mounting bracket bolts and 2 nuts.
6. Pull the FGCM out from behind the bracket while pulling the connectors through the bracket.

1. Install FGCM onto bracket while pulling connectors through bracket opening one by one.
2. Install the 2 FGCM mounting bracket bolts and tighten to 1.5 N.m (13 lb in).
3. Connect the 3 electrical connectors to the FGCM.
4. Install the mid ship tank cover. Refer to «Compressed Natural Gas Tank Cover Replacement - Midship Tank»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions)
5. Install the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/express-h1500/2013-2013/remont/charging-system/#battery-charging-system-and-starting-system) .

Scheme 69

LPG Tank Replacement (Aft Axle)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the LPG fuel tank shield fasteners (1).
3. Remove the LPG fuel tank shield fastener (1).
4. Remove the LPG fuel tank shield fasteners (1).
5. Remove the LPG fuel tank shield (2) from the vehicle.

1. Install the LPG fuel tank shield (2) to the vehicle.
2. Install the LPG fuel tank shield fasteners (1) and tighten to 8 (6 lb ft).
3. Install the LPG fuel tank shield fastener (1) and tighten to 8 (6 lb ft).
4. Remove the LPG fuel tank shield fasteners (1) and tighten to 8 (6 lb ft).
5. Lower the vehicle.

Scheme 70

Fuel Gauge Replacement (Aft Axle)

Scheme 71

LPG Fuel Pressure and Temperature Sensor Replacement (3 Tank)

Scheme 72

Liquefied Petroleum Gas Fuel Sender Control Module Replacement (Aft Axle)

1. Drain the fuel tank. Refer to «LPG Tank Drain and Evacuation»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-tank-drain-and-evacuation) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the LPG fuel tank access cover bolts (1).
4. Remove the LPG fuel tank access cover (2) and seal (3) from the LPG fuel tank.
5. Remove the LPG fuel tank access cover clamp (1).
6. Remove the LPG fuel tank fuel pump module hose (2).
7. Remove the LPG fuel tank fuel pump module nuts (1).
8. Remove the LPG fuel tank fuel pump module (2).

1. Remove the magnets from inside of the fuel tank, and clean any metal fragments or other debris from the magnets.
2. Using a clean rag, wipe the inside of the tank within arm's reach to remove any moisture or other contaminants.
3. Install the fuel tank magnets in their original positions.
4. Install the LPG fuel tank fuel pump module (2).
5. Install the LPG fuel tank fuel pump module nuts (1) and tighten to 18 (13 lb ft).
6. Install the LPG fuel tank fuel pump module hose (2).
7. Install the LPG fuel tank fuel pump module hose clamp (1).
8. Install the LPG fuel tank access cover (2) and seal (3) to the LPG fuel tank.
9. Install the LPG fuel tank access cover bolts (1) and tighten in a crisscross pattern to 17 (13 lb ft).
10. Lower the vehicle.
11. Purge the fuel tank. Refer to «LPG Tank Purge»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-tank-purge) .

Scheme 73

LPG Fuel Tank Fuel Pump and Fuel Tank Pressure Sensor Module Solenoid Replacement (Fuel Supply 3 Tank)

Scheme 74

LPG Fuel Tank Fuel Pump and Fuel Tank Pressure Sensor Module Solenoid Replacement (Bypass 3 Tank)

Scheme 75

LPG Tank Pressure Relief Valve Replacement (Aft Axle)

Scheme 76

LPG Fuel Tank Filler Valve Replacement (3 Tank)

Scheme 77

Liquefied Petroleum Gas Distributor Replacement

1. Drain the fuel lines. Refer to «LPG Fuel Line Draining»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-fuel-line-draining) , «LPG Fuel Line Draining (3 Tank Feed and Return)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-fuel-line-draining-3-tank) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the fuel feed hose (1) from the solenoid valve.
4. Remove the fuel feed hose retainer bolts (1) from the retainers (2).
5. Remove the fuel feed hose (3) from the frame.
6. Remove the fuel feed hose retainer bolt (1) from the retainers (2).
7. Remove the fuel feed hose (3) from the fuel filter.
8. Remove the fuel feed hose (3) from the vehicle.

1. Install the fuel feed hose (3) to the vehicle.
2. Install the fuel feed hose (3) to the fuel filter and tighten to 18 (13 lb ft).
3. Install the fuel feed hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
4. Install the fuel feed hose (3) to the frame.
5. Install the fuel feed hose retainer bolts (1) to the retainers (2) and tighten to 22 (16 lb ft).
6. Install the fuel feed hose (1) to the solenoid valve and tighten to 18 (13 lb ft).
7. Lower the vehicle.

1. Drain the fuel lines. Refer to «LPG Fuel Line Draining»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-fuel-line-draining) , «LPG Fuel Line Draining (3 Tank Feed and Return)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-fuel-line-draining-3-tank) .
2. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)
3. Remove the fuel feed hose (1) from the distribution block.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the fuel feed hose retainer bolt (1) from the retainer (2).
6. Remove the fuel feed hose (3) from the retainer (2) .
7. Remove the fuel feed hose retainer bolt (1) from the retainer (2).
8. Remove the fuel feed hose (3) from the retainer (2) .
9. Remove the fuel feed hose (1) from the fuel filter.
10. Remove the fuel feed hose (1) from the vehicle.

1. Install the fuel feed hose (1) to the vehicle.
2. Install the fuel feed hose (1) to the fuel filter and tighten to 18 (13 lb ft).
3. Install the fuel feed hose (3) to the retainer (2) .
4. Install the fuel feed hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
5. Install the fuel feed hose (3) to the retainer (2) .
6. Install the fuel feed hose retainer bolts (1) to the retainers (2) and tighten to 22 (16 lb ft).
7. Lower the vehicle.
8. Install the fuel feed hose (1) to the distribution block. and tighten to 18 (13 lb ft).
9. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)

Scheme 78

LPG Fuel Return Hose Replacement (Solenoid Valve to Fuel Tank Drain Valve 3 Tank)

1. Drain the fuel lines. Refer to «LPG Fuel Line Draining (3 Tank Feed and Return)»(/chevrolet/express-h1500/2013-2013/remont/testing-diagnostics/#engine-controlsfuel-48l-l20-53l-lmf-or-60l-l96-lc8-repair-instructions__lpg-fuel-line-draining-3-tank) .
2. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)
3. Remove the fuel return hose (1) from the distribution block.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-h1500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the fuel return hose retainer bolt (1) from the retainer (2).
6. Remove the fuel return hose (3) from the retainer (2) .
7. Remove the fuel return hose retainer bolt (1) from the retainer (2).
8. Remove the fuel return hose (3) from the retainer (2) .
9. Remove the fuel return hose retainer bolt (1) from the retainer (2).
10. Remove the fuel return hose (3) from the retainer (2) .
11. Remove the fuel return hose retainer bolt (1) from the retainer (2).
12. Remove the fuel return hose (3) from the retainer (2) .
13. Remove the fuel return hose retainer bolt (1) from the retainer (2).
14. Remove the fuel return hose (3) from the retainer (2) .
15. Remove the fuel return hose (1) from the fuel tank drain valve.
16. Remove the fuel return hose (1) from the vehicle.

1. Install the fuel return hose (1) to the vehicle.
2. Install the fuel return hose (1) to the fuel tank drain valve and tighten to 18 (13 lb ft).
3. Install the fuel return hose (3) to the retainer (2) .
4. Install the fuel return hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
5. Install the fuel return hose (3) to the retainer (2) .
6. Install the fuel return hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
7. Install the fuel return hose (3) to the retainer (2) .
8. Install the fuel return hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
9. Install the fuel return hose (3) to the retainer (2) .
10. Install the fuel return hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
11. Install the fuel return hose (3) to the retainer (2) .
12. Install the fuel return hose retainer bolt (1) to the retainer (2) and tighten to 22 (16 lb ft).
13. Lower the vehicle.
14. Install the fuel return hose (1) to the distribution block and tighten to 18 (13 lb ft).
15. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/express-h1500/2013-2013/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling)

Scheme 79

LPG Tank Filler Hose Replacement (Fill Valve to Filter 3 Tank)

Scheme 80

LPG Tank Filler Hose Replacement (Tank to Filter 3 Tank)

Scheme 81

LPG Fuel Filter Replacement (Feed Hose 3 Tank)

Scheme 82

LPG Fuel Filter Replacement (Fill Hose 3 Tank)

Scheme 83

LPG Tank Filler Valve Receptacle Replacement

Scheme 84

LPG Tank Fill Bleeder Valve Replacement (3 Tank)

See also:
• Diagnostic Trouble Code (DTC) List - Vehicle
• Brake Pedal Position Sensor Calibration
• Control Module References
• Battery Negative Cable Disconnection and Connection
• Lifting and Jacking the Vehicle
• Cooling System Draining and Filling (Static Fill)
• Cooling System Draining and Filling (Vac N Fill)
• Component Fastener Tightening Caution
• Fastener Caution
• Engine Cover Replacement
• Gasoline/Gasoline Vapors Warning
• Electrical Center Identification Views
• Battery Disconnect Warning
• Fuel Pressure Relief (CH-48027)
• Fuel Pressure Relief (Without CH-48027)
• Fuel Tank Draining (L59)
• Fuel Tank Draining (Without L59)
• Fuel Tank Replacement (E26)
• Road Test Warning
• Adhesives, Fluids, Lubricants, and Sealers
• Ignition System Specifications
• Special Tools (Diagnostic Tools)
• Trailer Hitch Platform Replacement
• Air Cleaner Assembly Replacement
• Fuel Pressure Relief (CH-48027)
• Fuel Pressure Relief (Without CH-48027)
• Fuel Tank Draining (L59)
• Fuel Tank Draining (Without L59)
• Fuel Tank Fuel Pump Module Replacement
• Metal Collar Quick Connect Fitting Service
• LPG Fuel Line Draining
• LPG Fuel Line Draining (3 Tank Feed and Return)
• Crankshaft Position System Variation Learn
• Compressed Natural Gas Tank Replacement - Cargo Tank
• LPG Tank Drain and Evacuation
• Compressed Natural Gas Fuel Pressure Relief (With CH-48027)
• Compressed Natural Gas Tank Venting
• LPG Tank Purge