I just did the fuel filters on the Express and I must have had a gallon of fuel drain out before it would stop. I know it always drains a good amount but this time was a waste of fuel.

As we get older , we get slower :Dlol. Napping under the van is a clever time waster , just don't take the filters off till after nap time !! I try to have two people when I change filters , one hands the other filter filled w/fuel to save cranking the engine .

I may have been napping

The best way to do it I found is to:
1) have less than half a tank of fuel
2) start with secondary filter (the spin on to the right) open the drain valve and check for water then close it.
3) break the vacuum seal on the filter by slowly turning it. Once the seal is broken you can spin the filter off with very little fuel loss.
4) put on new secondary filter.
5) open primary drain valve again check for water then close it.
6) use a socket to break the vacuum seal and loosen slowly (it will be full of fuel) and you will have some come out of the pump.
7) replace canister filter and reinstall. spray the water in fuel sensor connector with wire dryer or electric contact cleaner and plug it in.
8) put key in ignition and turn to run (not crank) pump will come on and you will hear it pushing fuel/air. Pump will run about 2 mins.
9) after pump stops turn off ign. and take key out for 1 min. then repeat step #8. Then repeat again one more time. Pump running a total of 6 mins.
10) check for leaks, both filters are full now.
11) start truck it should fire within 5 seconds, let idle it maybe rough for first 45 seconds then smooth out.
12) check for leaks again and water in fuel light. If no light/leaks you are good to go.

Now for some extra notes. I have replaced these filters 14 times thus far. And I have learned a few things. Step 8 & 9 are critical. 6 mins. sounds like alot but it isn't. I have tried 1 cycle and the truck would not fire. 2 cycles truck ran for 5 seconds then cut off. 3 cycles is the magic number:). Also it is pointless to drain the primary & secondary filters if you have not broken the vacuum seal on them. It will just keep pulling fuel out of the tank. It took me a couple of times to figure this out.

Make sure you buy the water separator wrench from Kennedy Diesel for the secondary filter. I found out the hard way on about my 8-9 filter change. I had been using a small pipe wrench to remove the separator and ended up rounding the edges off of it as it is plastic.

This piece is only available from GM and is 210.00:eek:. I even called junk yards looking for wreaked d-max vans and no one would just sell me the piece without buying to whole dam pump assy.

Have been changing with 1/4 tank and using ramps under front. I think all the fuel that drains out the bottom is whats in the filter