GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

The fuel system hose/pipes are serviceable individually or as a complete fuel/brake bundle assembly. The following procedure is for servicing the fuel hose/pipes individually.

    Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

  1. Remove the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

  3. Object Number: 1649002  Size: SH
  4. Disconnect the fuel feed hose/pipe fitting from the engine compartment fuel hose (2). Refer to Metal Collar Quick Connect Fitting Service.
  5. Plug the open ports to prevent fuel loss and contamination.
  6. Disconnect the evaporative emission (EVAP) quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service.
  7. Open the retainer (1) located on the front of dash. Remove the fuel and EVAP lines from the retainer.
  8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

  9. Object Number: 1653564  Size: SH
  10. Remove the fuel filter (3) and fuel filter bracket (2). Refer to Fuel Filter Replacement.
  11. Disconnect the fuel EVAP line fitting (6). Refer to Plastic Collar Quick Connect Fitting Service. Plug the open line fittings to prevent fuel loss and contamination.

  12. Object Number: 818896  Size: SH
  13. Pull the locking mechanism (1) outward in order to disengage the fuel/brake bundle chassis pipe retainers from the rail.

  14. Object Number: 785812  Size: MH
  15. Open the retainers (1) located at the forward portion of the rail in order to remove the chassis hose/pipes.
  16. Complete the following in order to remove the chassis hose/pipes from the retainers (2) located at the rearward portion of the rail:
  17. 12.1. Pull the retainers (2) free from the rail.
    12.2. Open the retainers (2) at the top.
    12.3. Remove the chassis hose/pipes from the retainers (2).
  18. Pull downward in order to disconnect the fuel/brake bundle chassis pipe retainer from the underbody.

  19. Object Number: 1649726  Size: SH
  20. Support the transmission with a suitable jack.
  21. Remove the bolts securing the transmission support to the underbody, from the right side only.
  22. Lower the transmission jack until there is enough room to allow removal of the chassis fuel hose/pipes. Pull down on the transmission support if necessary.
  23. With the aid of an assistant, support the front and rear of the chassis fuel hose/pipes.
  24. Carefully guide the chassis fuel hose/pipes down through the engine compartment, removing from the bottom.

Installation Procedure

  1. Clean any of the contamination from the male line ends and apply a few drops of clean engine oil.
  2. With the aid of an assistant, carefully guide the chassis fuel hose/pipes up through the engine compartment into position.

  3. Object Number: 1649726  Size: SH
  4. Guide the chassis fuel hose/pipes past the transmission support.
  5. Caution: Refer to Fastener Caution in the Preface section.

  6. Install the bolts securing the transmission support to the underbody and tighten to 60 N·m (44 lb ft).
  7. Remove the transmission jack.

  8. Object Number: 785812  Size: MH
  9. Push upward in order to connect the fuel/brake bundle chassis pipe retainer to the underbody.
  10. Complete the following in order to install the chassis hose/pipes to the retainers (2) located at the rearward portion of the rail:
  11. 7.1. Install the chassis hose/pipes into the retainers (2).
    7.2. Close the retainers (2) at the top.
    7.3. Insert the retainers (2) into the rail.
  12. Install the chassis hose/pipes into the retainers (1) located at the forward portion of the rail.
  13. Close the retainers.

  14. Object Number: 818896  Size: SH
  15. Push the locking mechanism (1) inward in order to engage the fuel/brake bundle chassis pipe retainers to the rail.

  16. Object Number: 1653564  Size: SH
  17. connect the EVAP line fitting (6). Refer to Plastic Collar Quick Connect Fitting Service.
  18. Install the fuel filter bracket (2) and filter (3). Refer to Fuel Filter Replacement.
  19. Lower the vehicle.

  20. Object Number: 1649002  Size: SH
  21. Insert the chassis hose/pipes into the retainer (1) located at front of dash.
  22. Close the retainer.
  23. Connect the EVAP quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service.
  24. Connect the engine compartment fuel hose fitting (2) to the chassis fuel pipe. Refer to Metal Collar Quick Connect Fitting Service.
  25. Install the fuel tank filler pipe cap.
  26. Check the fuel system for leaks.
  27. Install the engine sight shield. Refer to Intake Manifold Sight Shield Replacement.