GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Cadillac 🢒 1996 🢒 DeVille 🢒 Engine 🢒 Engine Controls - 4.0L and 4.6L 🢒 Fuel Hose and Pipes

Fuel Hose and Pipes Fuel and EVAP

Removal Procedure

Tools Required

Refer to J 37088-A , Fuel Pipe Separator Tool Set

Notice: Do Not attempt to repair the EVAP pipes or the connecting hoses. Replace the damaged EVAP pipes or the connecting hoses are damaged. If the nylon EVAP pipe becomes kinked and cannot be straightened, it must be replaced.

  1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Raise the vehicle.
  3. Remove retaining hardware for the section to be replaced.
  4. Inspect the location of attaching hardware for installation.

    5. Object Number: 12775 Size: SH
  5. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting.
  6. Repeat for the other fitting.

    7. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.


    Object Number: 12776 Size: SH
  7. Blow out dirt from quick connect fittings, using compressed air.

    8. Object Number: 12777 Size: SH
  8. Squeeze the plastic tabs of male end connector.

    9. Object Number: 12778 Size: SH
  9. Pull connection apart.
  10. Install the protective caps on pipe.

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.)

  1. Position the new fuel pipe in original location.
  2. Remove the protective caps from fuel pipe.

    3. Object Number: 12784 Size: SH
  3. Apply a few drops of clean engine oil to the male connector pipe end.

    4. Object Number: 12786 Size: SH
  4. Install the quick-connect fitting at fuel filter.
    5. 4.1. Push connector together to cause the retaining tabs/fingers to snap into place

    Object Number: 12786 Size: SH
  5. Pull on both ends of connection to make sure connection is secure once installed.
  6. Install retaining hardware.
  7. Lower the vehicle.
  8. Repeat the connect procedure for engine compartment fuel pipe quick-connectors.

    9. Object Number: 41527 Size: SH
  9. Tighten the fuel filler cap.
  10. Install the negative battery terminal.
  11. Inspect for leaks.
    12. 11.1. Turn the ignition switch ON for 2 seconds.
    11.2. Turn the ignition switch OFF for 5 seconds.
    11.3. Turn the ignition switch ON.
    11.4. Check for fuel leaks.

Fuel Hose and Pipes Fuel Filter to Fuel Sender

Removal Procedure

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.

  1. Remove the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Raise the vehicle and suitably support.

    4. Object Number: 23594 Size: SH
  4. Remove the quick-connect fittings at fuel feed (4) and return (6) pipes. Refer to In-Line Fuel Filter Replacement .
  5. Remove the hardware retaining section of hose to be replaced.

    6. Inspect the locaton of attaching hardware for installation.

  6. Remove the fuel tank. Refer to Fuel Tank Replacement .
  7. Remove the section of pipe to be replaced.

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.)

  1. Position the new fuel pipe in original location.
  2. Remove the protective caps from fuel pipe.

    3. Object Number: 12784 Size: SH
  3. Apply a few drops of clean engine oil to the male connector pipe end.

    4. Object Number: 12786 Size: SH
  4. Install the quick-connect fitting at fuel sender.
    5. 4.1. Push connector together to cause the retaining tabs/fingers to snap into place.

    Object Number: 12787 Size: SH
  5. Pull on both ends of connection to make sure connection is secure once installed.
  6. Install the fuel tank. Refer to Fuel Tank Replacement .
  7. Install the retaining hardware.
  8. Repeat connect procedure for fuel filter fuel pipe quick-connectors.
  9. Lower the vehicle.

    10. Object Number: 41527 Size: SH
  10. Tighten the fuel filler cap.
  11. Install the negative battery cable.
  12. Inspect for leaks.
    13. 12.1. Turn the ignition switch ON for 2 seconds.
    12.2. Turn the ignition switch OFF for 5 seconds.
    12.3. Turn the ignition switch ON.
    12.4. Check for fuel leaks.

Fuel Hose and Pipes Rear EVAP Pipe and Fuel Hose

Removal Procedure
  1. Relieve the fuel System Pressure. Refer to Fuel Pressure Relief Procedure .

    2. Object Number: 23594 Size: SH

    Notice: If the nylon pipes become kinked, and cannot be straightened, replace them.

       • Do Not attempt to repair sections of nylon pipes. If damaged, replace.
       • When replacing the vapor pipes, always replace them with original equipment or parts that meet GM specifications.
       • When replacing the vapor hoses, always replace them with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose.

  2. Remove the hardware retaining section of hose to be replaced.

    3. Note the location of attaching hardware for installation.

  3. Remove the fuel tank (1) if replacing vent valve (2) hose to EVAP canister. Refer to Fuel Tank Replacement .
  4. Remove the quick-connect fitting at fuel filter if replacing EVAP pipe from fuel filter to EVAP canister. Refer to Servicing Quick Connect Fittings .
  5. Remove the section of pipe or hose.
  6. Inspect the hoses for cuts, swelling, cracks and distortion.
  7. Replace the pipes or hoses as required.

Installation Procedure

    Object Number: 23594 Size: SH

    Notice: Follow the same routing as the original pipes and hoses. Secure the pipes and hoses in order to prevent chafing.

  1. Install the pipe or hose
  2. Install the fuel tank (1) if replacing vent valve hose to EVAP canister. Refer to Fuel Tank Replacement .
  3. Install the quick-connect fitting at fuel filter if replacing EVAP pipe from fuel filter to EVAP canister. Refer to Servicing Quick Connect Fittings .
  4. Install the retaining hardware.
  5. Inspect for leaks.
    6. 5.1. Turn the ignition switch ON for 2 seconds.
    5.2. Turn the ignition switch OFF for 5 seconds.
    5.3. Turn the ignition switch ON.
    5.4. Check for fuel leaks.