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.)
Replacement is by assembly only.
Steel Fuel Line Repair
Steel fuel lines are welded steel tubes, meeting the GM specifications 124-M or its equivalent. The fuel feed line is 3/8 inches diameter and the fuel return line is 5.16 inches diameter. Do not use copper or aluminum tubing in order to replace the steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibration.
- Cut a piece of fuel hose 4.0 inches (100 mm) longer than the section of line to be removed. If more than 6 inches (152 mm) is to be removed, use a combination of steel pipe and hose. The hose length should not be more than 10 inches total.
- Cut a section of the pipe to be replaced with a tube cutter. Use the first step to form a bead on the ends of the pipe and, also, on the new section of pipe, if used.
- Slide the hose clamps onto the pipe and push the hose 2.0 inches (51 mm) onto each portion of the fuel pipe. Tighten a clamp on each side of the repair.
- Secure the fuel line to the frame.
Coupled Hose Repair
Do not repair the coupled hoses and replace only as an assembly.
Uncoupled Hose Repair
Use only reinforced furl resistant hose, made of Fluoroelastomer material. Do not use a hose within 4 inches (100 mm) of any part of the exhaust system, or within 10 inches (2154 mm) of the catalytic converter. The hoses inside diameter must match the outside diameter of the steel tubing.
Clamps
These are stainless steel, screw bank-type clamps, P/N 2494772 or the equivalent.
Repair the steel vapor pipe in sections using a brazed seamless steel tubing meeting the GM Specification 123M, the equivalent, or a hose identified with the word Fluoroelastomer. An incorrectly marked hose could cause early failure or failure to meet emission standard.
Do not use copper or aluminum tubing in order to replace the steel tubing. Those materials do not have the satisfactory durability to withstand normal vehicle vibrations.
Do not use a rubber hose within 4 inches (100 mm) of any part of the exhaust system or within 10 inches (254 mm) of the catalytic converter. The hose's inside diameter must match the steel tubing's outside diameter.
In repairable areas, cut a piece of the fuel hose 4 inches (100 mm) longer than the portion of the line removed.
If you remove more than a 6 inch (152 mm) length of pipe, use a combination of steel tubing and hose so that hose lengths will not be more than 10 inches (254 mm).
Cut the ends of the pipe remaining on the vehicle square with a tube cutter. Using the first step of a double flaring tool, form a bead on the end of both pipe sections. If the pipe is too corroded to withstand the bead operation without damage, replace the pipe. If you use a new section of pipe, form a bead on both ends of it also.
Use a screw type hose clamp, P/N 2494772 or the equivalent. Slide the clamps onto the pipe, and push the hose 2 inches (51 mm) onto each portion of the fuel pipe. Tighten the clamps on each side of the repair.
