Removal Procedure
Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
Important: Always maintain cleanliness when servicing the fuel system components.
- Remove the fuel tank. Refer to Fuel Tank Replacement .
- Disconnect the fuel pipes (2,3) at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
- Cap the fuel sender fuel pipes and the fuel filter area pipes as needed in order to stop any fuel leakage.
- Remove the fuel pipe-attaching hardware.
- Remove the fuel feed and the fuel return pipes.
- Note the position of the fuel pipes and the fuel pipe-attaching hardware for installation.
Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
Installation Procedure
Caution: In order to reduce the risk of fire and personal injury observe the
following items:
• Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon fuel
pipes • Do not hammer directly on the fuel harness body clips when installing
new fuel pipes. Damage to the nylon pipes may result in a fuel leak. • Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. • Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection and prevent
a possible fuel leak. (During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.)
Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.Notice:
• Secure the fuel pipes to the frame in order to prevent chafing.
Maintain a minimum of 13 mm (½ inch) clearance around
a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm
(¾ inch) around any moving part. • Do not allow the fuel pipes to come into contact with the fuel
tank or underbody.
Notice: Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter.
Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.
- Install the new fuel feed and the fuel return pipes and the fuel pipe-attaching hardware as noted during the removal.
- Remove the caps from the fuel filter area pipes and from the fuel sender fuel pipes.
- Connect the fuel feed pipes (2,3) at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
- Inspect all the fuel pipe bundle clips and fasteners for correct installation.
- Install the fuel tank. Refer to Fuel Tank Replacement .
