Fuel Hose/Pipes Assembly Replacement Rear

Tools Required

Notice: Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter.

Notice: 

Important: Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Drain the fuel tanks. Refer to Fuel Tank Draining .
3. Remove the left muffler. Refer to Muffler Replacement .



4. Disconnect the tank crossover hose (3) at the left fuel tank.

Important: Do not disconnect the EVAP hose at the fuel tank roll over valve.

5. Carefully disconnect the EVAP hose at the T-connector (1).



6. Disconnect the fuel sender fuel feed pipe (3) (jet pump to left tank). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
7. Disconnect the fuel feed pipe (8) at the fuel filter. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
8. Disconnect the fuel feed rear crossover pipe (9) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
9. Disconnect the fuel return rear pipe (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .



10. Disconnect the fuel sender fuel feed pipe (7) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
11. Disconnect the fuel return rear pipe (3) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
12. Disconnect the fuel feed rear pipe (4) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
13. Remove the left side rear fuel pipes.
14. Cap the fuel sender pipes.
15. Cap the fuel filter inlet.
16. Cap the chassis fuel return pipe.



17. Remove the right muffler. Refer to Muffler Replacement .



18. Disconnect the crossover hose (3) at the right fuel tank.

Important: Do not disconnect the EVAP hose at the fuel tank roll over valve.

19. Carefully disconnect the EVAP hose at the T-connector (2).



20. Remove the fuel pipes from the two rear upper fuel and EVAP pipe retainers.



21. Disconnect the fuel sender fuel feed pipe (3) (jet pump to left tank). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
22. Disconnect the fuel feed rear crossover pipe (2) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
23. Remove the fuel sender fuel feed pipe (jet pump to left tank).
24. Remove the fuel feed rear crossover pipe (left tank to jet pump).
25. Cap the fuel sender pipes.



26. Disconnect the EVAP purge pipe (2) at the chassis EVAP purge pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
27. Cap the chassis EVAP purge pipe.



28. Remove the right fuel tank. Refer to Fuel Tank Replacement .
29. Disconnect the fuel tanks to canister EVAP pipe (2) at the canister. Refer to Plastic Collar Quick Connect Fitting Service .
30. Disconnect the EVAP purge pipe (1) at the canister. Refer to Plastic Collar Quick Connect Fitting Service .



31. Remove the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Rear End.
32. Disconnect the fuel tank vent valve hose (1) at the fuel tank vent valve (3).



33. Remove the rear EVAP pipes (1) and the EVAP hose (5) from the following straps:

•	The straps attached to the fuel pipes (2).

•	The straps attached to the parking brake cable (3).

•	The strap attached to the rear wheelhouse liner brace (4).

34. Remove the rear EVAP pipes and the EVAP hose.

1. Connect the fuel tank vent valve hose (1) to the fuel tank vent valve (3).



2. Connect the fuel tank vent valve hose (5) to the rear wheelhouse liner brace (4) with 1 strap.
3. Connect the fuel tank vent valve pipe (1) to the fuel pipes (2) with 2 straps.
4. Connect the fuel tank vent valve pipe to the parking brake cable (3) with 2 straps.
5. Install the right rear wheelhouse panel. Refer to Wheelhouse Panel Replacement .



6. Route the fuel tanks to canister EVAP pipe (2) through the right tunnel reinforcement opening.
7. Route the EVAP purge pipe through the right tunnel reinforcement opening.



8. Connect the fuel tanks to canister EVAP pipe (2) to the canister. Refer to Plastic Collar Quick Connect Fitting Service .
9. Connect the EVAP purge pipe (1) to the canister. Refer to Plastic Collar Quick Connect Fitting Service .
10. Install the right fuel tank. Refer to Fuel Tank Replacement .



11. Remove the cap from the chassis EVAP purge pipe.
12. Connect the EVAP purge pipe (2) to the chassis EVAP purge pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .




Important: Lubricate the fuel pipes in order to aid in installation. Use mechanic's wire attached to the fuel sender end of the fuel pipe in order to pull the fuel pipe through the tunnel reinforcement opening. Pull the fuel pipe through from the top down.

13. Install the fuel feed rear crossover pipe (2) (left tank to jet pump).
14. Install the fuel sender fuel feed pipe (3) (jet pump to left tank).
15. Remove the caps from the fuel sender pipes.
16. Connect the fuel sender fuel feed pipe (3) (jet pump to left tank). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
17. Connect the fuel feed rear crossover pipe (2) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .




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.

18. Install the fuel pipes into the two rear upper fuel and EVAP pipe retainers.

Tighten
Tighten the fuel and EVAP pipe retainer nuts to 3 N·m (27 lb in).




19. Remove the cap from the chassis fuel return pipe.

Important: Lubricate the fuel pipes in order to aid in installation. Use mechanic's wire attached to the fuel sender end of the fuel pipe in order to pull the fuel pipe through the tunnel reinforcement opening. Pull the fuel pipe through from the top down.

20. Install and connect the fuel return rear pipe (2). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
21. Install and connect the fuel feed rear crossover pipe (9) (left tank to jet pump). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
22. Remove the cap from the fuel filter inlet.
23. Install and connect the fuel feed pipe (8) at the fuel filter. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
24. Install and connect the fuel sender fuel feed pipe (3) (jet pump to left tank). Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .



25. Remove the caps from the fuel sender pipes.
26. Connect the fuel feed rear pipe (4) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
27. Connect the fuel return rear pipe (3) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
28. Connect the fuel sender fuel feed pipe (7) at the fuel sender. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .



29. Connect the EVAP hose at the T-connector (1).
30. Connect the tank crossover hose (3) at the left fuel tank.
31. Push the clamp outboard against the fuel tank keeping the clamp parallel with the white stripe on the tank crossover hose.

Tighten
Tighten the tank crossover hose clamp to 4 N·m (35 lb in).




32. Install the left muffler. Refer to Muffler Replacement .
33. Refill the fuel system.
34. Tighten the fuel filler cap.
35. Connect the negative battery cable.
36. Inspect for leaks.

36.1.

Turn the ignition switch ON for 2 seconds.

36.2.

Turn the ignition switch OFF for 10 seconds.

36.3.

Turn the ignition switch ON.

36.4.

Check for fuel leaks.

37. Perform the idle learn procedure. Refer to Idle Learn .