Removal Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
fuel leak. • Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. This will ensure proper reconnection
and prevent a possible fuel leak. (During normal operation, the O-rings located
in the female connector will swell and may prevent proper reconnection if
not lubricated.)
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.
Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
Important: Always maintain cleanliness when servicing fuel system components.
- Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Clean all the fuel and EVAP pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
- Disconnect the engine compartment connecting fuel feed pipe (4) from the chassis fuel and EVAP pipes. Refer to Metal Collar Quick Connect Fitting Service .
- Disconnect the engine compartment connecting return pipe (3) from the chassis fuel and EVAP pipes.
- Disconnect the engine compartment connecting EVAP pipe (5) from the chassis fuel and EVAP pipes.
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle in general information.
- Remove the rear fuel pipe shield attaching nuts (3) and bolt (6).
- Remove the rear fuel pipe shield (4).
- Remove the front fuel pipe shield attaching nuts (1).
- Remove the front fuel pipe shield.
- Disconnect the fuel feed pipe from the outlet side (4) of the fuel filter (3). Discard the O-ring.
- Disconnect the fuel return pipe (1) and the EVAP (2) pipe from the rear fuel and EVAP pipes.
- Remove the fuel pipe attaching hardware and the fuel pipes. Note the position of the fuel pipes for installation.
- Inspect the pipes for bends, kinks, and cracks. Repair or replace the pipes as required.
Repair Procedure
When repairing the fuel or EVAP pipes with hoses, always replace them with original equipment or parts meeting GM specifications. Use only reinforced fuel resistant hose which is 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.
A minimum of 13 mm (½ in) clearance must be maintained around sharp edges such as flanges, pinch welds, etc., in order to prevent contact and chafing. A minimum of 19 mm (¾ in) clearance must be maintained around all moving parts.
Cut the ends of the pipe remaining on the car square with a tube cutter. Using the first step of a double flaring tool, form a bead on the end of both pipe sections. If the pipe is too corroded to withstand the beading operation without damage, the pipe should be replaced. If a new section of pipe is used, form a bead on both ends of the pipe also.
Use screw type hose clamps. Slide the clamps onto the pipe and push the hose 51 mm (2 in) onto each portion of the fuel pipe.
If more than a 6 in length of pipe is removed, use a combination of steel pipe and hose so that the total hose lengths, including the 100 mm (4 in) additional length will not be more than 254 mm (10 in) long. Follow the same routing as the original pipe.
Installation Procedure
Important:
• Always re-attach the fuel lines and the fuel filter with all original
type fasteners and hardware. • When replacing the fuel or EVAP pipes, always replace them with
original equipment or parts that meet the GM specifications for those parts.
The replacement pipes must have the same type of fittings as the original
pipes in order to ensure the integrity of the connection. • Do Not use copper or aluminum tubing to replace steel tubing.
Only tubing meeting the 124-M specification or its equivalent is capable
of meeting all pressure, corrosion and vibration characteristics necessary
to ensure the durability standard required.
- Position the fuel and EVAP pipes to the frame rail.
- Loosely install the number 1 position pipe clip stud.
- Loosely install the number 2 position pipe clip stud.
- Loosely install the number 3 position pipe clip stud.
- Align the fuel and EVAP pipes to the number 5 and number 6 position.
- Install the pipe clip bolts.
- Align the fuel and EVAP pipes to the number 4 position clamp.
- Install the pipe clamp stud.
- Connect the fuel return pipe (1) at the rear quick connect fitting.
- Connect the EVAP purge pipe (2) at the rear quick connect fitting.
- Connect the fuel feed pipe (4) to the fuel filter (3).
- Install the fuel and EVAP pipes into the pipe clip.
- Align the fuel and EVAP pipes in a flat position.
- Install the pipe clip bolt.
- Position the front fuel pipe shield (2) to the 3 fuel pipe clip studs and the brake pipe clip stud (7).
- Install the pipe shield nuts (1).
- Position the rear fuel pipe shield (4) to the fuel pipe stud and the fuel pipe clip stud (5).
- Loosely install the pipe shield nuts.
- Install the pipe shield bolt.
- Tighten the pipe shield bolt to 5 N·m (44 lb in).
- Tighten the pipe shield nuts to 5 N·m (44 lb in).
- Lower the vehicle.
- Connect the engine compartment EVAP pipe (5) to the chassis EVAP pipe.
- Connect the engine compartment fuel feed pipe (4) to the chassis fuel feed pipe.
- Connect the engine compartment fuel return pipe (3) to the chassis fuel feed pipe.
- Add fuel and reinstall the fuel fill cap.
- Reconnect the negative battery cable.
- Inspect for leaks.
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.
Tighten
Tighten the pipe clip bolts to 4.5 N·m (40 lb in).
Tighten
Tighten the pipe clamp stud to 5 N·m (44 lb in).
Tighten
Tighten the fuel feed pipe fitting to 30 N·m (22 lb
ft).
Tighten
Tighten the pipe clip bolt to 5.5 N·m (49 lb in).
Tighten
Tighten the pipe shield nuts to 5 N·m (44 lb in).
Tighten
| 26.1. | Turn the ignition switch ON for 2 seconds. |
| 26.2. | Turn the ignition switch OFF for 10 seconds. |
| 26.3. | Turn the ignition switch ON. |
| 26.4. | Check for fuel leaks. |
