Fuel Hose/Pipes Assembly Replacement (Fuel Pipes)

REMOVAL PROCEDURE





NOTE:
^ 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.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Disconnect the fittings (1) at the engine compartment fuel feed and return pipes.
4. Disconnect the fuel pipe attaching hardware (2).




5. Disconnect the fuel feed and return pipe quick connects at the fuel filter and the fuel return pipe.




6. Remove the hardware retaining section of pipe to be replaced (1). Note location of attaching hardware for installation.




7. Remove the section of pipe and hoses.
8. Remove rust or burrs from the engine compartment fuel pipes by the following procedure:
8.1. Use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
8.2. Using a clean shop towel, wipe off the male tube ends.
8.3. Inspect all the connectors for dirt and burrs. Clean or replace the components/assemblies as required.
8.4. Disconnect the fuel feed and return pipe quick connects at the fuel tank pipe harness (2).
8.5. Remove the section of fuel pipe from the hardware retaining mounts (1).
8.6. Remove the fuel tank.
8.7. Refer to Fuel Tank Replacement (Passenger/Cargo Van) and Fuel Tank Replacement (Commercial/RV Cutaway Van).

INSTALLATION PROCEDURE





NOTE: Refer to Fastener Notice in Service Precautions.

1. Connect the fuel feed and return pipes to the engine fuel pipes (1).

Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.

2. Position new fuel pipe harness in original location and fuel pipe harness attaching hardware (2).




3. Connect the fuel feed pipe to the fuel filter and connect the fuel return pipes together.




4. Install the new section of fuel feed and return pipe making sure that they are fully seated into the pipe attaching hardware (1).




5. Install the fuel tank and attaching hardware (1) if the tank was removed.
6. Connect the fuel feed and return pipe quick connects fittings at the rear frame rails (2).
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Check for fuel leaks.
9.1. Turn the ignition switch to the ON position for 2 seconds.
9.2. Turn the ignition switch to the OFF position for 10 seconds.
9.3. Again, turn the ignition switch to the ON position.
9.4. Check for fuel leaks.