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 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: 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.
Notice: Cap the fittings and plug the holes when servicing the fuel system in
order to prevent dirt and other contaminants from entering the open
pipes and passages.
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.
Important: Always maintain cleanliness when servicing fuel system components.
- Relieve the fuel system
fuel pressure. Refer to
Fuel Pressure Relief
.
- Clean all engine fuel pipe connections.
- Clean areas surrounding the engine fuel pipe connections.
- Remove the fuel feed and fuel return pipe quick-connect fitting
in the engine compartment. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Raise the vehicle. Refer
to
Lifting and Jacking the Vehicle
in
General Information.
- Disconnect the fuel return pipe quick-connect fitting in front
of the fuel tank. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the fuel feed pipe threaded fitting on the engine-side
of the in-pipe fuel filter.
- Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the
fuel return pipe as needed to stop any fuel leakage.
- Remove the fuel feed, fuel return, EVAP pipe attaching hardware.
- Note the position of the fuel and EVAP pipes and the fuel and
EVAP pipe attaching hardware for installation.
- Inspect the pipes for bends, kinks and cracks.
- Repair or replace the pipe or pipes as required.
Installation 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.) |
Notice:
| • | Secure the fuel pipes to the frame in order to prevent chafing.
Maintain a minimum of 13 mm (½ inch) clearance around
a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm
(¾ inch) around any moving part. |
| • | Do not allow the fuel pipes to come into contact with the fuel
tank or underbody. |
Notice: Always re-attach the fuel lines and fuel filter with all original type
fasteners and hardware.
Do not repair sections of fuel pipes.
- Install the new fuel feed,
fuel return, and EVAP pipes and the fuel and EVAP pipe attaching hardware
as noted during removal.
Important: If fuel line bundle attaching hardware is damaged or broken replace
it.
- Remove the caps from the in-pipe fuel filter pipe, the fuel feed
pipe, and the fuel return pipe.
- Connect the fuel return pipe quick-connect fitting in front of
the fuel tank. Refer to
Plastic Collar Quick Connect Fitting Service
.
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.
- Connect the fuel
feed pipe threaded fitting at the outlet of the in pipe fuel filter.
Tighten
Tighten The in-pipe fuel filter fitting to 30 N·m (22 lb ft).
- Inspect and make sure all of the fuel pipe bundle clips, and fasteners
are properly installed.
- Lower the vehicle.
- Connect the fuel feed
(1), and fuel return pipe (2) quick-connect fittings in the engine compartment.
Refer to
Plastic Collar Quick Connect Fitting Service
.
- Tighten the fuel fill cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks.
| 10.1. | Turn ON the ignition for 2 seconds. |
| 10.2. | Turn OFF the ignition for 10 seconds. |
| 10.3. | Turn ON the ignition. |
| 10.4. | Inspect for fuel leaks. |
- Install the fuel injection sight shield. Refer to
Fuel Injector Sight Shield Replacement
in Engine Mechanical.
