Removal Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
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. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. 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.)
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.
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: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
Important: Always maintain cleanliness when servicing the fuel system components.
- Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Remove the fuel tank. Refer to Fuel Tank Replacement .
- Disconnect the fuel feed pipe, the fuel return pipe, and EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
- Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
- Remove the hardware attaching the fuel feed pipe, the fuel return pipe, and the EVAP pipe, and remove the pipes.
- Note the position of the pipes and the attaching hardware for the installation.
Installation Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.
Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.Notice:
• Secure the fuel pipes to the frame in order to prevent chafing.
Maintain a minimum of 13 mm (½ inch) clearance around
a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm
(¾ inch) around any moving part. • Do not allow the fuel pipes to come into contact with the fuel
tank or underbody.
- Install the new fuel feed pipe, the fuel return pipe, and the EVAP pipe and the attaching hardware as noted during removal.
- Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
- Connect the quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
- Ensure all of the fuel pipe bundle clips and fasteners are properly installed.
- Install the fuel tank. Refer to Fuel Tank Replacement .
- Lower the vehicle.
- Add fuel and install the fuel fill pipe cap.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Inspect for fuel leaks:
| 9.1. | Turn the ignition ON for 2 seconds. |
| 9.2. | Turn the ignition OFF for 10 seconds. |
| 9.3. | Turn the ignition ON. |
| 9.4. | Inspect for fuel leaks. |
