Fuel Hose/Pipes Replacement - Chassis Front

Tools Required

J 34730-1A Fuel Pressure Gauge

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the engine cover. Refer to Engine Cover Replacement .
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
4. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system.



5. Disconnect the fuel feed and return pipes (8) from the engine compartment fuel pipes.
6. Cap the engine compartment fuel pipes.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Remove the fuel pipes retainer mounting stud (7) from the cylinder head.
9. Remove the fuel pipes retainer mounting stud (6) from the transmission.
10. Remove the fuel pipes retainer mounting fastener (5) from the crossrail.



11. Remove the fuel pipes from the transfer case bracket clip (4 wheel drive only).



12. Disconnect the chassis fuel feed (1) and return pipes (2) at the rear fuel pipes.
13. Cap the rear fuel pipes.
14. Note the position of the fuel pipes for aid in installation.
15. Remove the fuel pipes from the retaining clips.
16. Remove the fuel pipes.

Important: 

•	When replacing the fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection.

•	Do Not use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required.

1. Remove the caps from the rear fuel pipes.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Connect the chassis fuel feed pipe (1) at the fuel filter.

Tighten
Tighten the fuel feed pipe fitting to 27 N·m (20 lb ft).

3. Connect the fuel return pipe at the coupler (2).

Tighten
Tighten the return pipe fitting to 27 N·m (20 lb ft).




4. Install the fuel pipes into the transfer case bracket clip (4 wheel drive only).



5. Install the fuel pipes into the transmission bracket retainer.
6. Install mounting stud (6).

Tighten
Tighten the mounting stud to 7 N·m (62 lb in).

7. Install the fuel pipes into the cylinder head retainer.
8. Install the mounting stud (7).

Tighten
Tighten the mounting stud to 33 N·m (24 lb ft).

9. Install the fuel pipes into the crossrail retainer.
10. Install the fuel pipes retainer mounting fastener (5) to the crossrail.

Tighten
Tighten the mounting fastener to 11 N·m (97 lb in).

11. Lower the vehicle.
12. Remove the caps from the engine compartment fuel pipes.
13. Connect the fuel feed and return pipes (8) to the engine compartment fuel pipes.

Tighten
Tighten the fuel feed and return pipe fittings to 30 N·m (22 lb ft).

14. Tighten the fuel filler cap.
15. Connect the negative battery cable.
16. Inspect for leaks.

16.1.

Turn ON the ignition for 2 seconds.

16.2.

Turn OFF the ignition for 10 seconds.

16.3.

Turn ON the ignition.

16.4.

Inspect for fuel leaks.

17. Install the engine cover. Refer to Engine Cover Replacement .

Fuel Hose/Pipes Replacement - Chassis Rear

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel filler cap.
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .



4. Disconnect the front fuel pipes (3) and EVAP pipe (4) from the rear chassis pipes (1), (2).
5. Drain gasoline into an approved container.



6. Disconnect the fuel feed pipe (1) from the fuel filter.
7. Discard the O-ring.
8. Disconnect the fuel return pipe from the coupler (2).
9. Discard the O-ring.
10. Disconnect the EVAP line.



11. Disconnect the fuel return (4), fuel feed (6), and EVAP line (7) from the fuel tank lines (5). Refer to Plastic Collar Quick Connect Fitting Service .
12. Release the fuel pipe grommet (2) from crossrail.
13. Remove the fuel pipe retainer fastener (3) from crossrail.
14. Release the fuel pipes from retainer and grommet.

Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. 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. Install the new O-rings on the engine fuel feed and return pipes.
2. Position the fuel pipes into crossrail retainer and crossrail grommet.
3. Position the new fuel pipe harness through the crossrails in the original location.



4. Loosely assemble fuel feed pipe (1) to fuel filter.
5. Loosely assemble fuel return pipe to coupler (2).



6. Install fuel pipe grommet (2) into crossrail.

Lubricate the grommet to aid in installation.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

7. Install fuel pipe retainer fastener to crossrail.

Tighten
Tighten fuel pipe crossrail retainer to 11 N·m (97 lb in).

Tighten
Tighten fuel feed pipe to fuel filter attaching nut to 27 N·m (20 lb ft) using a back-up wrench.

Tighten
Tighten fuel return pipe to coupler (1) attaching nut to 27 N·m (20 lb ft) using a back-up wrench.

8. Apply a few drops of clean engine oil to the rear male connector pipe ends.
9. Connect the fuel return (4), fuel feed (6), and EVAP line (7) to the fuel tank lines (5). Refer to Plastic Collar Quick Connect Fitting Service .
10. Tighten the fuel filler cap.
11. Connect the negative battery cable.
12. Inspect for a fuel leak.

14.1.

Turn ON the ignition for 2 seconds.

14.2.

Turn OFF the ignition for 10 seconds.

14.3.

Turn ON the ignition.

14.4.

Inspect for fuel leaks.