For 1990-2009 cars

## Fuel Hose and Pipes Engine to Fuel Sender

### Removal Procedure

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief .
2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. Refer to Servicing Quick Connect Fittings .
3. Plug fuel lines.
4. Raise vehicle.
5. Remove the quick-connect fittings at fuel sender and nylon fuel feed and return connecting lines. Refer to Servicing Quick Connect Fittings .
6. Plug fuel lines to prevent leakage.
7. Remove the fuel pipe mounting hardware from pipes.
8. Remove the fuel pipes to be serviced.

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.

• | Using a clean shop towel, wipe off male tube ends.

• | Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required.

• | In the repairable areas, cut a piece of fuel hose 100 mm (4") longer than portion of the line removed. If more than a 152 mm (6") 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"), including hose overlap on fuel line.

### Installation Procedure

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

10.1. | Turn ignition to ON position for 2 seconds.

10.2. | Then turn to OFF for 10 seconds.

10.3. | Turn the ignition to ON position.

10.4. | Check for fuel leaks.

## Fuel Hose and Pipes EVAP

### 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.

1. Remove the retaining hardware and clamp as necessary.
2. Note location and position for future reference.

Important: Inspect hoses and vapor lines for cuts, swelling, cracks, kinks and distortion.

3. Remove the pipe or hose.

### Installation Procedure

1. Install the vapor line or hose.

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

2. Install the retaining hardware and clamps.