GM Service Manual Online
For 1990-2009 cars only

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 fuel system components.


    Object Number: 699561  Size: SH
  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Note the position of the fuel, the evaporative emission (EVAP) pipes and the attaching hardware for installation.
  3. Disconnect the fuel feed (2), the fuel return (2) and the EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
  5. Remove the fuel feed, the fuel return and the EVAP pipe attaching hardware.
  6. Remove the fuel feed (2), the fuel return (2) and the EVAP pipes from the fuel tank.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

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.


    Object Number: 699561  Size: SH
  1. Install the new fuel feed (2), the fuel return (2) and the EVAP pipes to the fuel tank.
  2. Install the fuel feed, the fuel return and the EVAP pipe attaching hardware.
  3. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
  4. Connect the fuel feed (2), the fuel return (2) and the EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Ensure that all of the fuel pipe bundle clips, and fasteners are properly installed.
  6. Install the fuel tank. Refer to Fuel Tank Replacement .