For 1990-2009 cars

### Removal Procedure

#### Tools Required

J 37088-A, Tool Set, Fuel Line Quick-Connect Separator

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Clean all the fuel and EVAP pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system.
5. Disconnect the engine compartment fuel feed pipe (2) from the chassis fuel feed pipe (3). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
6. Disconnect the engine compartment EVAP pipe (5) from the chassis EVAP pipe (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Remove the rear fuel pipe shield attaching nuts (3) and bolt (6).
9. Remove the rear fuel pipe shield (4).
10. Remove the front fuel pipe shield attaching nuts (1).
11. Remove the front fuel pipe shield (2).
12. Disconnect the fuel feed pipe (1) from the outlet side of the fuel filter (2). Discard the O-ring.
13. Disconnect the EVAP purge pipe (3) at the rear quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
14. Disconnect the fuel return pipe (4) at the rear quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
15. Remove the fuel pipe attaching hardware and the fuel pipes. Note the position of the fuel pipes for installation.
16. 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:

• | 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.

1. Position the fuel and EVAP pipes to the frame rail.

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.

2. Loosely install the number 1 position pipe clip stud.
3. Loosely install the number 2 position pipe clip stud.
4. Loosely install the number 3 position pipe clip stud.

Tighten
Tighten the 3 studs to 5 N·m (44 lb in).

5. Align the fuel and EVAP pipes to the number 5 and number 6 position.
6. Install the front pipe clip bolts.

Tighten
Tighten the front pipe clip bolts to 4.5 N·m (40 lb in).

7. Align the fuel and EVAP pipes to the number 4 position clamp.
8. Install the pipe clamp stud.

Tighten
Tighten the pipe clamp stud to 5 N·m (44 lb in).

9. Connect the fuel return pipe (4) at the rear quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
10. Connect the EVAP purge pipe (3) at the rear quick connect fitting. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
11. Connect the fuel feed pipe (1) to the fuel filter (2).

Tighten
Tighten the fuel feed pipe fitting to 30 N·m (22 lb ft).

12. Install the fuel and EVAP pipes into the rear pipe clip.
13. Align the fuel and EVAP pipes in a flat position.
14. Install the rear pipe clip bolt.

Tighten
Tighten the rear pipe clip bolt to 5.5 N·m (49 lb in).

15. Position the front fuel pipe shield (2) to the 3 fuel pipe clip studs and the brake pipe clip stud (7).
16. Install the pipe shield nuts (1).

Tighten
Tighten the pipe shield nuts to 5 N·m (44 lb in).

17. Position the rear fuel pipe shield (4) to the fuel pipe stud and the fuel pipe clip stud (5).
18. Loosely install the pipe shield nuts (3).
19. Install the pipe shield bolt (6).

Tighten

1. Tighten the pipe shield bolt to 5 N·m (44 lb in).
2. Tighten the pipe shield nuts to 5 N·m (44 lb in).

20. Lower the vehicle.
21. Connect the engine compartment EVAP pipe (5) to the chassis EVAP pipe (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
22. Connect the engine compartment fuel feed pipe (2) to the chassis fuel feed pipe (3). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
23. Refill the fuel tank.
24. Tighten the fuel filler cap.
25. Connect the negative battery cable.
26. Inspect for leaks.

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. | Inspect for fuel leaks.

27. Perform the Idle Learn Procedure. Refer to Idle Learn .