Fuel Hose and Pipes Assembly Replacement

Fuel Lines - These are welded steel tubes, meeting the GM Specifications 124-M, or its equivalent. The fuel feed line is 3/8 inch diameter and the fuel return line is 5/16 inch diameter. Do not use copper or aluminum tubing in order to replace the steel tubing. Those materials do not have satisfactory durability in order to withstand normal vehicle vibration.

Coupled hose - These are not to be repaired. Replace the coupled hoses only as an assembly.

Uncoupled hose - 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 (254 mm) of the catalytic converter. The hose's inside the diameter must match the outside diameter of the steel tubing.

Clamps - These are stainless steel, screw banktype clamps, PN 2494772, or the equivalent.

1. Cut a piece of fuel hose 4 inches (100 mm) longer than the section of line to be removed. If you are removing more than 6 inches (152 mm), use a combination of steel pipe and hose. The hose length should not be more than 10 inches total.
2. Cut a section of the pipe to be replaced with a tube cutter. Use the first step of a double flaring tool in order to form a bead on the ends of the pipe and also on the new section of pipe, if used.
3. Slide the hose clamps onto the pipe and push the hose 2 inches (51 mm) onto each portion of the fuel pipe.
4. Tighten a clamp on each side of the repair.
5. Secure fuel line to the frame.
6. Check for leaks.