For 1990-2009 cars

## Fuel Hose and Pipes Engine Compartment Fuel Pipe

### Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. Refer to Servicing Quick Connect Fittings (Metal Collar) .
3. Plug the fuel lines.
4. Remove the engine fuel feed and return pipe retainer and screws.
5. Remove the fuel return pipe from the fuel pressure regulator using a back-up wrench.
6. Remove the fuel pipe from fuel rail.

Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

7. Discard O-rings.

### Installation Procedure

1. Remove the plugs on the fuel pipes.
2. Install the new O-rings.
3. Install the fuel return pipe to the fuel pressure regulator.

Tighten
Tighten the retainer screw to the regulator to 6 N·m (53 lbs in)

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.

4. Install the fuel feed pipe to the fuel rail using a back-up wrench.

Tighten
Tighten the fuel fitting to 30 N·m (22 lbs ft)

5. Install the quick-connect fittings. Refer to Servicing Quick Connect Fittings (Metal Collar) .
6. Install the fuel line retainer.
7. Install the fuel line clamp screws.

Tighten
Fuel line clamp screws to 10 N·m ( 89 lbs in)

8. Install the negative battery cable.
9. Install the fuel filler cap.
10. Inspect for fuel leaks through the following steps:

10.1. | Turn the ignition switch to the ON position for two seconds.

10.2. | Turn the ignition switch to the OFF position for ten seconds.

10.3. | Turn the ignition switch to the ON position.

10.4. | Check for fuel leaks.

## Fuel Hose and Pipes EVAP Pipes/Lines

### Removal Procedure

Caution: In order to reduce the risk of fire and personal injury observe the following items:

• | Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

• | Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a 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.

• | Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.)

Caution: In order to reduce the risk of fire and personal injury observe the following items:

• | Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

• | Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a 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.

• | Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.

1. Remove the retaining hardware and clamps as necessary.
2. Note the location and position for future reference.
3. Inspect the hoses and vapor lines for cuts, swelling, cracks, kinks and distortion.
4. Remove the pipe or hose.

### Installation Procedure

Important: Follow the same routing as the original pipe or hose.

1. Install the vapor line or hose.
2. Install the retaining hardware and clamps.

## Fuel Hose and Pipes Chassis Fuel Pipes/Hoses

### Removal Procedure

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure
2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. Refer to Servicing Quick Connect Fittings (Metal Collar)
3. Plug fuel lines.
4. Raise vehicle.

Caution: Provide additional support when a vehicle is on a hoist in the following ways:

• | Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.

• | Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.

Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
5. Remove the quick-connect fittings at fuel sender and nylon fuel feed and return connecting lines. Refer to Servicing Quick Connect Fittings (Metal Collar)
6. Plug the fuel pipes to prevent leakage.
7. Remove the fuel pipe mounting hardware from pipes.

Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

8. Remove the fuel pipes to be serviced.
9. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the line removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including hose overlap on fuel line.

### Installation Procedure

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.

1. Position the fuel pipe in the body clips.
2. Install the fuel pipe and hose hardware.
3. Remove the caps on the fuel pipes.
4. Install the quick-connect fittings on the fuel pipes. Refer to Servicing Quick Connect Fittings (Metal Collar) .
5. Lower the vehicle.
6. Remove the caps covering the fuel lines if required.
7. Install the engine compartment fuel line quick-connect fittings. Refer to Servicing Quick Connect Fittings (Metal Collar) .
8. Install the fuel filler cap.
9. Install the negative battery cable.
10. Inspect for fuel leaks through the following steps:

10.1. | Turn the ignition switch to the ON position for two seconds.

10.2. | Turn the ignition switch to the OFF position for ten seconds.

10.3. | Turn the ignition switch to the ON position.

10.4. | Check for fuel leaks.