Removal Procedure
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.
- Remove the fuel tank. Refer to
Fuel Tank Replacement
.
- Disconnect the fuel feed and fuel return pipe quick-connect fittings
at the fuel sender assembly. Refer to
Plastic Collar Quick Connect Fitting Service
.
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.
Important: Note the position of the pipes and the attaching hardware for installation.
- Remove the attaching hardware from the following pipes and remove the
pipes:
| • | The evaporative emission (EVAP) pipe |
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: 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. |
Notice:
| • | Do not attempt to straighten kinked nylon pipes. Replace any kinked
nylon pipes in order to prevent damage to the vehicle. |
| • | Do not attempt to repair sections of nylon pipes. Replace damaged
nylon pipes. |
| • | Replace the vapor pipes with original equipment or parts that
meet GM specifications. |
| • | Replace the vapor hoses with original equipment or parts meeting
GM specifications. Use only reinforced fuel-resistant hose identified with
the word Fluoroelastomer or GM 6163M on the hose. |
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.
- Install the following pipes and install the attaching hardware to the
pipes as noted during removal:
| • | The evaporative emission (EVAP) pipe |
- Remove the caps from the in-pipe fuel filter pipes and the fuel
sender fuel pipes.
- Install the fuel feed
and fuel return pipe quick-connect fittings at the fuel sender assembly. Refer
to
Plastic Collar Quick Connect Fitting Service
.
- Inspect and make sure all of the fuel pipe bundle clips, and fasteners
are properly installed.
- Install the fuel tank. Refer to
Fuel Tank Replacement
.
