Removal Procedure
Tools Required
J 37088-A Fuel Line Disconnect Tool Set
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.
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.
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.
Important: Always maintain cleanliness when servicing fuel system components.
- Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
- Clean all of the engine fuel pipe connections.
- Clean the areas surrounding the engine fuel pipe connections.
- Remove the fuel feed (1) and fuel return pipe (2) quick-connect fitting in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Cautions and Notices.
- Remove the quick-connect fitting at the fuel return pipe in front of the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
- Disconnect the feed pipe threaded fitting on the engine-side of the in-pipe fuel filter.
- Cap the fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
- Remove the fuel feed, the fuel return, and the EVAP pipe attaching hardware and pipes.
- Note the position of the fuel and EVAP pipes and hardware for installation.
- Inspect the pipes for bends, kinks, and cracks.
- Repair or replace any pipes as necessary.
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.
Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.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.
- Install the new fuel feed, the fuel return, and hardware as noted during the removal.
- Inspect and ensure that all of the fuel pipe bundle clips and fasteners are properly installed.
- Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
- Connect the quick-connect fitting at the fuel return pipe in front of the fuel tank. Refer to Metal Collar Quick Connect Fitting Service .
- Connect the feed pipe threaded fitting at the outlet of the fuel filter.
- Ensure that all of the fuel pipe bundle clips and fasteners are properly installed.
- Lower the vehicle.
- Connect the fuel feed (1) and the fuel return pipe (2) quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
- Add fuel and tighten the fuel filler cap.
- Inspect for leaks.
Important: If fuel line bundle attaching hardware is damaged or broken replace the hardware.
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.
Tighten
Tighten the fitting to 30 N·m (22 lb ft).
| 10.1. | Turn the ignition switch on for 2 seconds. |
| 10.2. | Turn the ignition switch off for 10 seconds. |
| 10.3. | Turn the ignition switch on. |
| 10.4. | Inspect for fuel leaks. |
