Fuel Hose and Pipes Chassis Fuel Pipes/Hose

Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the fuel feed pipe quick-connect fitting at the engine compartment. Refer to Servicing Quick Connect Fittings .
3. Remove the fuel return pipe quick-connect fitting at the engine compartment. Refer to Servicing Quick Connect Fittings .
4. Plug the fuel lines to prevent leakage.
5. Raise the vehicle.

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

•	Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

•	Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
6. Remove the fuel feed pipe quick-connect fitting at the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings
7. Remove the fuel return pipe quick-connect fitting at the fuel tank. Refer to Servicing Quick Connect Fittings .
8. Plug the fuel lines to prevent leakage.
9. Remove the exhaust heat shield.



10. Remove the fuel pipe mounting bolts from the body clips.

In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the line removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including hose overlap on fuel line.




11. Remove the fuel pipes from the body clips.



12. Remove the fuel pipes (1) to be serviced.

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.

1. Install the fuel pipe (1) and hose hardware.



2. Position the fuel pipe in the body clips.



3. Install the fuel pipe mounting bolts into the body clips.

Tighten
Tighten the bolts to 6.0 N·m(53 lb in ).

4. Install the exhaust heat sheild.

Tighten
Tighten the exhaust shield bolt to 2.0 N·m(18 lb in ). Tighten the exhaust shield nuts to 1.0N·m(9 lb in).

5. Remove the caps on the lines.
6. Install the fuel feed pipe quick-connect fitting at the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings .
7. Install the fuel return pipe quick-connect fitting at the fuel tank. Refer to Servicing Quick Connect Fittings .
8. Lower the vehicle.
9. Remove the caps on the fuel lines.
10. Install the fuel feed pipe quick-connect fitting at the engine compartment Refer to Servicing Quick Connect Fittings .
11. Install the fuel return pipe quick-connect fitting at the engine compartment Refer to Servicing Quick Connect Fittings .
12. Install the fuel filler cap.
13. Connect the negative battery cable.
14. Inspect for fuel leaks through the following steps:

14.1.

Turn the ignition switch to the ON position for two seconds.

14.2.

Turn the ignition switch to the OFF position for ten seconds.

14.3.

Turn the ignition switch to the ON position.

14.4.

Check for fuel leaks.

Fuel Hose and Pipes Engine Fuel Pipes/Hose

Tools Required

J 37088-A tool set, Fuel Pipe Quick-Connect Separator.

Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel feed pipe or the engine fuel return pipe.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
3. Remove the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings .
4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
5. Remove the upper intake manifold assembly. Refer to Upper Intake Manifold .



6. Remove the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.



7. Remove the engine fuel feed pipe from the fuel rail. Discard the O-ring.

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.

1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.



2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

Tighten
Tighten the engine fuel pipe fittings to 17 N·m (13 lb ft).




3. Install the upper intake manifold assembly. Refer to Upper Intake Manifold .
4. Install the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings .
5. Tighten the fuel tank filler pipe cap.
6. Install the negative battery cable.

Fuel Hose and Pipes EVAP Pipes

Caution: In order to Reduce the Risk of Fire and Personal Injury:

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.

1. Remove the retaining hardware and the clamp as necessary.
2. Note the location and the position for future reference.
3. Inspect the hoses and the vapor lines for cuts, swelling, cracks, kinks and distortion.
4. Remove the pipe or the hose.

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.

Important: Follow the same routing as original pipe or hose.

1. Install the vapor line or hose.
2. Install the retaining hardware and clamps.