GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

The fuel system hose/pipes are serviceable individually or as a complete fuel/brake bundle assembly, the following procedure is servicing the fuel hose/pipes individually.

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

  2. Object Number: 785815  Size: MH
  3. Refer to Metal Collar Quick Connect Fitting Service in order to disconnect the following quick connect fittings from the fuel rail:
  4. • The return hose/pipe (1)
    • The feed hose/pipe (2)
    • Plug the open outlet ports to prevent fuel loss and contamination.
  5. Disconnect the evaporative emission (EVAP) quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service .
  6. Open the retainer (4) located at the engine control module (ECM) bracket in order to remove the chassis hose/pipes.

  7. Object Number: 818895  Size: SH
  8. Open the retainer located at the shock tower in order to remove the chassis hose/pipes.
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  10. Object Number: 785816  Size: SH
  11. Refer to Plastic Collar Quick Connect Fitting Service in order to disconnect the following quick connect fittings from the chassis bundle:
  12. • The fuel filter
    • The fuel return hose
    • The fuel EVAP hose
    • Plug the open outlet ports to prevent fuel loss and contamination.

    Object Number: 818896  Size: SH
  13. Pull the locking mechanism (1) outward in order to disengage the fuel/brake bundle chassis pipe retainers from the rail.

  14. Object Number: 785812  Size: MH
  15. Open the retainers (1) located at the forward portion of the rail in order to remove the chassis hose/pipes.
  16. Complete the following in order to remove the chassis hose/pipes from the retainers (2) located at the rearward portion of the rail:
  17. 10.1. Pull the retainers (2) free from the rail.
    10.2. Open the retainers (2) at the top.
    10.3. Remove the chassis hose/pipes from the retainers (2).

    Object Number: 785814  Size: MH
  18. Pull downward in order to disconnect the fuel/brake bundle chassis pipe retainer from the underbody.
  19. Remove the bolt securing the fuel filter bracket to the body.
  20. Remove the following from the fuel filter bracket:
  21. • The fuel return hose
    • The fuel EVAP hose

    Object Number: 818897  Size: SH
  22. Remove the bolts securing the transmission support to the underbody, from the right side only.

  23. Object Number: 818898  Size: SH
  24. Pull the right side transmission support down only enough to allow removal of the chassis fuel hose/pipes.
  25. Partially lower the hoist only enough to simultaneously gain access to both the front and rear portions of the chassis fuel hose/pipes.
  26. With the aid of an assistant, carefully guide the chassis fuel hose/pipes down through the engine compartment, removing from the bottom.

Installation Procedure

  1. Clean any of the contamination from the male line ends and apply a few drops of clean engine oil.
  2. With the aid of an assistant, carefully guide the chassis fuel hose/pipes up through the engine compartment into position.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  4. Object Number: 818898  Size: SH
  5. Pull the right side transmission support down only enough to allow installation of the chassis fuel hose/pipes.
  6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 818897  Size: SH
  7. Install the bolts securing the transmission support to the underbody.
  8. Tighten
    Tighten the transmission support bolts to 60 N·m (44 lb ft).


    Object Number: 785814  Size: MH
  9. Install the following to the fuel filter bracket:
  10. • The fuel return hose
    • The fuel EVAP hose
  11. Install the bolt securing the fuel filter bracket to the body.
  12. Tighten
    Tighten the fuel filter bracket bolt to 9 N·m (80 lb in).

  13. Push upward in order to connect the fuel/brake bundle chassis pipe retainer to the underbody.

  14. Object Number: 785812  Size: MH
  15. Complete the following in order to install the chassis hose/pipes to the retainers (2) located at the rearward portion of the rail:
  16. 9.1. Install the chassis hose/pipes into the retainers (2).
    9.2. Close the retainers (2) at the top.
    9.3. Insert the retainers (2) into the rail.
  17. Install the chassis hose/pipes into the retainers (1) located at the forward portion of the rail.
  18. Close the retainers.

  19. Object Number: 818896  Size: SH
  20. Push the locking mechanism (1) inward in order to engage the fuel/brake bundle chassis pipe retainers to the rail.

  21. Object Number: 785816  Size: SH
  22. Refer to Plastic Collar Quick Connect Fitting Service in order to connect the following quick connect fittings to the chassis bundle:
  23. • The fuel filter
    • The fuel return hose
    • The fuel EVAP hose
  24. Lower the vehicle.

  25. Object Number: 818895  Size: SH
  26. Insert the chassis hose/pipes into the retainer located at the shock tower.
  27. Close the retainer.

  28. Object Number: 785815  Size: MH
  29. Insert the chassis hose/pipes into the retainer (4) located at the ECM bracket.
  30. Close the retainer (4).
  31. Connect the EVAP quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service .
  32. Refer to Metal Collar Quick Connect Fitting Service in order to connect the following quick connect fittings to the fuel rail:
  33. • The feed hose/pipe (2)
    • The return hose/pipe (1)