GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

  1. Relieve the fuel system pressure. Refer to the Caterpillar Service Manual.
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the engine cover. Refer to Engine Cover Replacement .

  4. Object Number: 816418  Size: SH
  5. Disconnect the fuel return pipe from the engine. Refer to Metal Collar Quick Connect Fitting Service .
  6. 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.


    Object Number: 816399  Size: SH
  7. Disconnect the fuel feed pipe from the fuel filter . Refer to Metal Collar Quick Connect Fitting Service .
  8. Lower the fuel tanks, if required.

  9. Object Number: 816417  Size: SH
  10. Disconnect the chassis fuel feed and return pipe from the flexible feed and return pipe. Refer to Metal Collar Quick Connect Fitting Service .

  11. Object Number: 816418  Size: SH
  12. Unclip the fuel pipe bundle retaining clips.
  13. Remove the fuel pipes from the fuel bundle retaining clips.

Installation Procedure


    Object Number: 816418  Size: SH
  1. Position the fuel pipes to the fuel bundle retaining clips.
  2. Fasten the fuel pipe bundle retaining clips.
  3. Connect the chassis fuel feed and return pipe to the flexible feed and return harness. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the fuel tank if required.

  5. Object Number: 816415  Size: SH
  6. Connect the fuel feed pipes to the fuel filter . Refer to Metal Collar Quick Connect Fitting Service .

  7. Object Number: 816418  Size: SH
  8. Connect the fuel return pipe to the engine. Refer to Metal Collar Quick Connect Fitting Service .
  9. Refill the tank.
  10. Tighten the filler cap.
  11. Connect the negative battery cable.
  12. Inspect for leaks using the following procedure.
  13. Install the engine cover. Refer to Engine Cover Replacement .