For 1990-2009 cars

## Fuel Hose and Pipes Tank to Filter

### 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: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief
2. Drain the fuel tank. Refer to Fuel Tank Draining
3. Remove the fuel tank. Refer to Fuel Tank Replacement
4. Remove the quick-connect fittings on the fuel sender assembly side of the in-pipe fuel. Refer to Servicing Quick Connect Fittings
5. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
6. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware and the fuel feed, fuel return, and EVAP pipes.
7. Note the position of the fuel and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation.

### Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

1. Install the new fuel feed, fuel return, pipes and the fuel pipe attaching hardware as noted during removal.
2. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
3. New plastic connector retainers on the in-pipe fuel filter pipes and on the fuel sender fuel pipes.
4. Install the quick-connect fittings. Refer to Servicing Quick Connect Fittings
5. Install the fuel tank. Refer to Fuel Tank Replacement
6. Add fuel and install the fuel tank filler pipe cap.
7. Tighten the fuel tank filler pipe cap.
8. Install the negative battery cable.
9. Inspect for fuel leaks.

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

9.2. | Turn the ignition switch to the OFF for ten seconds.

9.3. | Again turn the ignition switch to the ON position.

9.4. | Check for fuel leaks.

## Fuel Hose and Pipes Filter to Engine

### Removal Procedure

#### Tool Required

J 37088-A tool set, Fuel Pipe Quick-Connect Separator

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: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief
2. Clean all engine fuel pipe connections.
3. Clean areas surrounding the engine fuel pipe connections.
4. Remove the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings
5. Raise the vehicle.
6. Remove the quick-connect fitting on the engine-side of the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings
7. Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
8. Remove the fuel feed, and fuel return pipe attaching hardware and the fuel feed, and fuel return pipes.
9. Note the position of the fuel pipes and the fuel pipes attaching hardware for installation.
10. Inspect the pipes for bends, kinks and cracks.
11. Replace the pipe or pipes as required.

### Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

1. Install the new fuel feed, fuel return, pipes and the fuel pipe attaching hardware as noted during removal.
2. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
3. New plastic connector retainers on the fuel return pipes.
4. Install the quick-connect fitting at the in-pipe fuel filter. Refer to Servicing Quick Connect Fittings
5. Lower the vehicle.
6. Install the quick-connect fittings in the engine compartment Refer to Servicing Quick Connect Fittings
7. Add fuel and install the fuel tank filler pipe cap.
8. Tighten the fuel tank filler pipe cap.
9. Install the negative battery cable.
10. Inspect for fuel leaks.

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

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

10.3. | Again turn the ignition switch to the ON position.

10.4. | Check for fuel leaks.

## Fuel Hose and Pipes Engine Pipes

### Removal Procedure

#### Tools Required

J 37088-A tool set, Fuel Pipe Quick-Connect Separator.

Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel feed pipe or the engine fuel return pipe.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief
2. Clean all engine fuel pipe connections.
3. Clean areas surrounding the engine fuel pipe connections.
4. Remove the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings
5. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
6. Remove the upper intake manifold assembly.
7. Remove the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.
8. Remove the engine fuel feed pipe from the fuel rail. Discard the O-ring.

### Installation Procedure

1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.
2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

Tighten
Tighten the engine fuel pipe fittings to 17 N·m(13 lb. ft.).

3. Install the upper intake manifold assembly. Refer to Upper Intake Manifold
4. Install the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings
5. Tighten the fuel tank filler pipe cap.
6. Install the negative battery cable.

## Fuel Hose and Pipes EVAP Pipes

### Removal Procedure

Notice: Do Not attempt to repair the EVAP pipes or the connecting hoses. Replace the damaged EVAP pipes or the connecting hoses are damaged. If the nylon EVAP pipe becomes kinked and cannot be straightened, it must be replaced.

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 hardware retaining the EVAP pipes. Note the location of the attaching hardware for installation.
2. Remove the EVAP pipes at the EVAP canister.
3. Remove the EVAP pipes at the fuel tank
4. Remove the EVAP pipes.

### Installation Procedure

Important: Route the replacement EVAP pipe in the same manner as the original EVAP pipe was routed.

1. Install the EVAP pipes into the vehicle.
2. Install the EVAP pipes onto the fuel tank.

Notice: Properly secure the EVAP pipe in order to prevent chafing of the pipe.

3. Install the EVAP pipes onto the EVAP canister.
4. Install the hardware retaining the EVAP pipe.