Fuel Hose/Pipes Assembly Replacement Fuel Pipe Repair

Steel fuel lines--These are welded steel tubes, meeting GM specifications 124-M, or the equivalent. The fuel feed line is 9.525 mm (3/8 inches) diameter and the fuel return line is 7.9375 mm (5/16 inches) diameter. DO NOT use copper or aluminum tubing to replace steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibration.

Coupled hose--DO NOT repair the hoses. Replace hoses only as an assembly.

Uncoupled hose - Use only reinforced fuel resistant hose, made of Fluoroelastomer material. Do not use a hose within 100 mm (4 inches) of any part of the exhaust system, or within 2154 mm (10 inches) of the catalytic converter. The hoses inside diameter must match the outside diameter of the steel tubing.

Clamps--These are stainless steel, screw bank-type clamps, #2494772, or equivalent.

1. Cut a piece of fuel hose 100 mm (4 inches) longer than the section of line to be removed. If you remove more than 152 mm (6 inches), use a combination of steel pipe and hose. The hose length should not be more than 254 mm (10 inches) total.
2. With a tube cutter, cut a section of the pipe to replace. Use the first step on the reamer 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 51 mm (2 inches) onto each portion of the fuel pipe. Tighten a clamp on each side of the repair.
4. Secure fuel line to the frame.
5. Inspect for leaks.

Fuel Hose/Pipes Assembly Replacement Rear

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Remove the pickup box. Refer to Pickup Box Replacement in Body Rear End.
4. Clean all the fuel pipe connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
5. Disconnect the rear fuel feed pipe (6) from the chassis fuel feed pipe.
6. Disconnect the rear fuel return pipe (5) from the chassis fuel return pipe.
7. Disconnect the fuel feed pipe (3) and the fuel return pipe (7) from the fuel sender (8).
8. Remove the fuel feed and return pipes.
9. Cap the fuel pipes in order to prevent possible fuel system contamination.

1. Remove the caps from the fuel and evaporative emission (EVAP) pipes.
2. Connect the rear fuel return pipe (5) to the chassis fuel return pipe.
3. Connect the rear fuel feed pipe (6) to the chassis fuel feed pipe.
4. Connect the fuel feed pipe (3) and the fuel return pipe (7) to the fuel sender (8).
5. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.
6. Lower the vehicle.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Inspect for leaks.

9.1.	Turn ON the ignition for 2 seconds.

9.2.	Turn OFF the ignition for 10 seconds.

9.3.	Turn ON the ignition.

9.4.	Inspect for fuel leaks.