Tool Required

J 37088-A Fuel Pipe Disconnect Tool Set

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.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Clean all engine fuel pipe connections.
4. Clean the areas surrounding the engine fuel pipe connections.
5. Disconnect the quick-connect fittings from the fuel feed pipe and the fuel return pipe in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .



6. Disconnect the quick-connect fitting from the fuel return pipe in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
7. Disconnect the threaded fitting from the fuel feed pipe on the engine-side of the in-pipe fuel filter.
8. Cap the following pipes as needed to stop any fuel leakage:

•	The in-pipe fuel filter pipe

•	The fuel feed pipe

•	The fuel return pipe

Important: Note the position of the pipes and the attaching hardware for installation.

9. Remove the attaching hardware from the following pipes and remove the pipes:

•	The fuel feed pipe

•	The fuel return pipe

•	The evaporative emission (EVAP) pipe

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.

10. Inspect the pipes for bends, kinks and cracks.
11. Repair or replace the pipe or pipes as required.

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.)

Notice: 

•	Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.

•	Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.

•	Replace the vapor pipes with original equipment or parts that meet GM specifications.

•	Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.

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.

Important: If fuel line bundle attaching hardware is damaged or broken replace the hardware.

1. Install the following pipes and install the attaching hardware to the pipes as noted during removal:

•	The fuel feed pipe

•	The fuel return pipe

•	The evaporative emission (EVAP) pipe

2. Remove the caps from the following pipes:

•	The in-pipe fuel filter pipe

•	The fuel feed pipe

•	The fuel return pipe

3. Connect the fuel return pipe quick-connect fitting in front of the fuel tank. Refer to 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.

4. Reconnect the fuel feed pipe threaded fitting at the outlet of the in pipe fuel filter.

Tighten
Tighten the fitting to 30 N·m (22 lb ft).

5. Lower the vehicle.



6. Connect the fuel feed, and fuel return pipe quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
7. Add fuel and reinstall the fuel tank filler pipe cap.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



9. Inspect and make sure all of the fuel pipe bundle clips, and fasteners are properly installed.
10. Inspect the fuel system for leaks by performing the following steps:

10.1.

Turn ON the ignition for 2 seconds.

10.2.

Turn OFF the ignition for 10 seconds.

10.3.

Turn ON the ignition.

10.4.

Inspect for fuel leaks.