GM Service Manual Online
For 1990-2009 cars only

Fuel Hose/Pipes Replacement - Chassis Pickup

Removal Procedure


    Object Number: 674616  Size: SH
  1. Disconnect the fuel feed and return pipes from the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
  2. Remove the fuel bundle bracket nut.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  4. Object Number: 737687  Size: SH
  5. Remove the fuel bundle clips (2) from the transmission brackets (1).
  6. Disconnect the chassis harness from the retaining clips.
  7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .

  8. Object Number: 877717  Size: SH
  9. Disconnect the chassis fuel pipes from the fuel tank pipes. Refer to Plastic Collar Quick Connect Fitting Service .

  10. Object Number: 877716  Size: SH
  11. Remove the fuel bundle nuts from the chassis.

  12. Object Number: 379478  Size: SH
  13. Loosen the electronic brake control module (EBCM) bracket bolts (4).
  14. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
  15. Remove the fuel bundle using the following procedure:
  16. 11.1. Guide the fuel bundle (2) pipes towards the rear of vehicle to clear the engine.
    11.2. Lower the fuel bundle while moving it foreword and out.

Installation Procedure


    Object Number: 877716  Size: SH
  1. Install the fuel pipe bundle using the following procedure:
  2. 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle.
    1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections.

    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.

  3. Install the fuel bundle nuts to the chassis.
  4. Tighten
    Tighten the nuts to 16 N·m (12 lb ft).


    Object Number: 877717  Size: SH
  5. Connect the chassis fuel pipes to the fuel tank pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .

  7. Object Number: 737687  Size: SH
  8. Connect the fuel bundle clips (2) to the transmission brackets (1).

  9. Object Number: 379478  Size: SH
  10. Tighten the EBCM bracket bolts (4).
  11. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  12. Lower the vehicle.

  13. Object Number: 674616  Size: SH
  14. Install the fuel bundle bracket.
  15. Install the fuel bundle bracket nut.
  16. Tighten
    Tighten the nut to 16 N·m (12 lb ft).

  17. Connect the fuel feed and return pipes to the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
  18. Purge the air from the fuel system.

Fuel Hose/Pipes Replacement - Chassis Cab/Chassis

Removal Procedure


    Object Number: 674616  Size: SH
  1. Disconnect the fuel feed and return pipes from the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
  2. Remove the fuel bundle bracket nut.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  4. Object Number: 737687  Size: SH
  5. Remove the fuel bundle clips (2) from the transmission brackets (1).
  6. Disconnect the chassis harness from the retaining clips.
  7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .

  8. Object Number: 877717  Size: SH
  9. Disconnect the chassis fuel pipes from the fuel tank pipes. Refer to Plastic Collar Quick Connect Fitting Service .

  10. Object Number: 877715  Size: SH
  11. Remove the fuel bundle nuts from the chassis.

  12. Object Number: 379478  Size: SH
  13. Loosen the electronic brake control module (EBCM) bracket bolts (4).
  14. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
  15. Remove the fuel bundle using the following procedure:
  16. 11.1. Guide the fuel bundle (2) pipes towards the rear of vehicle to clear the engine.
    11.2. Lower the fuel bundle while moving it foreword and out.

Installation Procedure


    Object Number: 877715  Size: SH
  1. Install the fuel pipe bundle using the following procedure:
  2. 1.1. Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle.
    1.2. Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections.

    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.

  3. Install the fuel bundle nuts to the chassis.
  4. Tighten
    Tighten the nuts to 16 N·m (12 lb ft).


    Object Number: 877717  Size: SH
  5. Connect the chassis fuel pipes to the fuel tank pipes. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .

  7. Object Number: 737687  Size: SH
  8. Connect the fuel bundle clips (2) to the transmission brackets (1).

  9. Object Number: 379478  Size: SH
  10. Tighten the EBCM bracket bolts (4).
  11. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  12. Lower the vehicle.

  13. Object Number: 674616  Size: SH
  14. Install the fuel bundle bracket.
  15. Install the fuel bundle bracket nut.
  16. Tighten
    Tighten the nut to 16 N·m (12 lb ft).

  17. Connect the fuel feed and return pipes to the chassis pipes. Refer to Metal Collar Quick Connect Fitting Service .
  18. Purge the air from the fuel system.

Fuel Hose/Pipes Replacement - Chassis Cab/Chassis w/Balance Pump

Removal Procedure


    Object Number: 877754  Size: SH
  1. Remove the front fuel tank. Refer to Fuel Tank Replacement .
  2. Remove the auxiliary fuel tank. Refer to Fuel Tank Replacement .
  3. Disconnect the pressure balance pump electrical connector (1).

  4. Object Number: 877720  Size: SH
  5. Remove the fuel pipes bundle nuts.
  6. Remove the fuel pipes bundle.

Installation Procedure


    Object Number: 877720  Size: SH
  1. Install the fuel pipes bundle.
  2. 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.

  3. Install the fuel pipes bundle nuts.
  4. Tighten
    Tighten the nuts to 16 N·m (12 lb ft).


    Object Number: 877754  Size: SH
  5. Connect the pressure balance pump electrical connector (1).
  6. Install the auxiliary fuel tank. Refer to Fuel Tank Replacement .
  7. Install the front fuel tank. Refer to Fuel Tank Replacement .