GM Service Manual Online
For 1990-2009 cars only

Fuel Hose/Pipes Replacement - Chassis Regular Cab

Removal Procedure


    Object Number: 1876017  Size: SH

    Note: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief.
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.

  7. Object Number: 1701047  Size: SH
  8. Remove the fuel pipe bracket nut from the bellhousing stud.

  9. Object Number: 1855293  Size: SH
  10. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  11. Unclip the oxygen sensor harness connector from the bracket.
  12. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.

  13. Object Number: 1855649  Size: SH
  14. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  15. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.

  16. Object Number: 1855296  Size: SH
  17. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  18. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  19. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  20. Unclip the inline harness connector from the bracket.
  21. Remove the fuel line bracket bolt (1).
  22. Remove the fuel/EVAP line clip nut (2).
  23. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines.
  24. Unclip the line assembly from the frame.
  25. Remove the fuel/EVAP line clips from the frame and crossmember.
  26. Remove the fuel/EVAP line assembly from the vehicle.

Installation Procedure


    Object Number: 1855296  Size: SH
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Clip the line assembly to the frame.
  3. Tighten the BPMV bolts.
  4. Install the fuel/EVAP line bracket locator tab to the frame.
  5. Install the fuel/EVAP line clips to the frame and crossmember.
  6. Clip the inline electrical connector to the bracket.
  7. Caution: Refer to Fastener Caution in the Preface section.

  8. Install the fuel/EVAP line bracket bolt (1).
  9. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  10. Install the fuel/EVAP line clip nut (2).
  11. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  12. Remove the caps from the fuel and EVAP lines.
  13. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  14. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.

  15. Object Number: 1855649  Size: SH
  16. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  17. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line.

  18. Object Number: 1855293  Size: SH
  19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  20. Install the fuel line clip (1) to the bracket on the automatic transmission.

  21. Object Number: 1701047  Size: SH
  22. Install the fuel pipe bracket nut to the bellhousing stud.
  23. Tighten
    Tighten the nut to 25 N·m (18 lb ft).

  24. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.
  25. Lower the vehicle.

  26. Object Number: 1876017  Size: SH
  27. Remove the caps from the fuel rail and EVAP line.
  28. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  29. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  30. Install the fuel fill cap.
  31. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  32. Use the following procedure in order to inspect for leaks:
  33. 24.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    24.2. Turn the ignition OFF for 10 seconds.
    24.3. Turn the ignition ON, with the engine OFF.
    24.4. Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Extended Cab

Removal Procedure


    Object Number: 1876017  Size: SH

    Note: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief.
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.

  7. Object Number: 1701047  Size: SH
  8. Remove the fuel pipe bracket nut from the bellhousing stud.

  9. Object Number: 1855293  Size: SH
  10. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  11. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.

  12. Object Number: 1855664  Size: SH
  13. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  14. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line.

  15. Object Number: 1855297  Size: SH
  16. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  17. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service.
  18. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  19. Remove the fuel line bracket bolt (1).
  20. Remove the fuel/EVAP line clip nut (2).
  21. Remove the fuel/EVAP line clips from the frame and crossmember.
  22. Remove the fuel/EVAP line assembly from the vehicle.

Installation Procedure


    Object Number: 1855297  Size: SH
  1. Position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the fuel/EVAP line bracket bolt (1).
  6. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  7. Install the fuel/EVAP line clip nut (2).
  8. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the chassis EVAP line quick connect fitting to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service.
  11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.

  12. Object Number: 1855664  Size: SH
  13. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  14. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line.

  15. Object Number: 1855293  Size: SH
  16. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  17. Install the fuel line clip (1) to the bracket on the automatic transmission.

  18. Object Number: 1701047  Size: SH
  19. Install the fuel pipe bracket nut to the bellhousing stud.
  20. Tighten
    Tighten the nut to 25 N·m (18 lb ft).

  21. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.
  22. Lower the vehicle.

  23. Object Number: 1876017  Size: SH
  24. Remove the caps from the fuel rail and EVAP line.
  25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  27. Install the fuel fill cap.
  28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  29. Use the following procedure in order to inspect for leaks:
  30. 21.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    21.2. Turn the ignition OFF for 10 seconds.
    21.3. Turn the ignition ON, with the engine OFF.
    21.4. Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Extended Cab - w/8 Ft Bed

Removal Procedure


    Object Number: 1876017  Size: SH

    Note: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.

  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief.
  2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.

  7. Object Number: 1701047  Size: SH
  8. Remove the fuel pipe bracket nut from the bellhousing stud.

  9. Object Number: 1855293  Size: SH
  10. Remove the fuel line clip (1) from the bracket on the automatic transmission.
  11. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.

  12. Object Number: 1855687  Size: SH
  13. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
  14. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.

  15. Object Number: 1855299  Size: SH
  16. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  17. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  18. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  19. Remove the fuel line bracket bolt (2).
  20. Remove the fuel/EVAP line clip nut (1).
  21. Remove the fuel/EVAP line clips from the frame and crossmember.
  22. Remove the fuel/EVAP line assembly from the vehicle.

  23. Object Number: 1855298  Size: SH
  24. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  25. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  26. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
  27. Remove the fuel line bracket bolt (1).
  28. Remove the fuel/EVAP line clip nut (2).
  29. Remove the fuel/EVAP line clips from the frame and crossmember.
  30. Remove the fuel/EVAP line assembly from the vehicle.

Installation Procedure


    Object Number: 1855298  Size: SH
  1. If equipped with 4WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  2. Install the fuel/EVAP line bracket locator tab to the frame.
  3. Install the fuel/EVAP line clips to the frame and crossmember.
  4. Caution: Refer to Fastener Caution in the Preface section.

  5. Install the fuel/EVAP line bracket bolt (1).
  6. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  7. Install the fuel/EVAP line clip nut (2).
  8. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  9. Remove the caps from the fuel and EVAP lines.
  10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.

  12. Object Number: 1855299  Size: SH
  13. If equipped with 2WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle.
  14. Install the fuel/EVAP line bracket locator tab to the frame.
  15. Install the fuel/EVAP line clips to the frame and crossmember.
  16. Install the fuel/EVAP line bracket bolt (2).
  17. Tighten
    Tighten the bolt to 9 N·m (80 lb in).

  18. Install the fuel/EVAP line clip nut (1).
  19. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  20. Remove the caps from the fuel and EVAP lines.
  21. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
  22. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.

  23. Object Number: 1855687  Size: SH
  24. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
  25. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.

  26. Object Number: 1855293  Size: SH
  27. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  28. Install the fuel line clip (1) to the bracket on the automatic transmission.

  29. Object Number: 1701047  Size: SH
  30. Install the fuel pipe bracket nut to the bellhousing stud.
  31. Tighten
    Tighten the nut to 25 N·m (18 lb ft).

  32. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.
  33. Lower the vehicle.

  34. Object Number: 1876017  Size: SH
  35. Remove the caps from the fuel rail and EVAP line.
  36. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  37. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  38. Install the fuel fill cap.
  39. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  40. Use the following procedure in order to inspect for leaks:
  41. 29.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    29.2. Turn the ignition OFF for 10 seconds.
    29.3. Turn the ignition ON, with the engine OFF.
    29.4. Inspect for fuel leaks.