Fuel Hose/Pipes Assembly Replacement

FUEL HOSE/PIPES ASSEMBLY REPLACEMENT

TOOL REQUIRED
J 34730-1A Fuel Pressure Gage

LEFT FUEL TANK PIPES REMOVAL PROCEDURE




1. Disconnect the negative battery cable.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tanks. Refer to Fuel Tank Draining Procedure.
4. Remove the left muffler.
5. Disconnect the tank crossover hose (5) at the left fuel tank.
6. Disconnect the evaporative emission (EVAP) pipe (2) at the left tank EVAP pipe (1).

NOTE: Refer to EVAP Pipes and Hoses Notice in Service Precautions.

7. Cap the EVAP pipe in order to prevent possible contamination.




8. Disconnect the auxiliary fuel return pipe (1) from the jet pump to the left tank.

NOTE:
- Do not repair the fuel feed or return pipes.
- Replace the fuel feed and return pipes with original equipment or with parts that meet the GM specifications for those parts. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.

IMPORTANT Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.

9. Disconnect the fuel return pipe (7) at the fuel filter and pressure regulator.
10. Disconnect the fuel feed pipe (8) at the fuel filter/pressure regulator.
11. Disconnect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.




12. Remove the left fuel tank shield mount nut (3).
13. Remove the left fuel tank shield mount bolt (2).
14. Remove the left fuel tank shield (1).




15. Disconnect the auxiliary fuel return rear pipe (1) at the fuel sender.
16. Disconnect the fuel return rear pipe (2) at the fuel sender.
17. Disconnect the fuel feed rear pipe (3) at the fuel sender.
18. Remove the left side rear fuel pipes.
19. Cap the fuel sender pipes.
20. Cap the fuel filter and pressure regulator.

LEFT FUEL TANK PIPES INSTALLATION PROCEDURE




1. Remove the caps from the fuel filter/pressure regulator.

IMPORTANT: Lubricate the fuel pipes in order to aid in installation. Use mechanic's wire attached to the fuel sender end of the fuel pipe in order to pull the fuel pipe through the tunnel reinforcement opening. Pull the fuel pipe through from the top down.

2. Install and connect the fuel return rear pipe (7) to the fuel filter and pressure regulator.
3. Install and connect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.
4. Install and connect the fuel feed pipe (8) at the fuel filter and pressure regulator.
5. Install and connect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank.




6. Remove the caps from the fuel sender pipes.
7. Connect the fuel feed rear pipe (3) at the fuel sender.
8. Connect the fuel return rear pipe (2) at the fuel sender.
9. Connect the auxiliary fuel return rear pipe (1) at the fuel sender.




10. Install the left fuel tank shield (1).
11. Install the mount bolt (2) for the left fuel tank shield (2).
12. Install the mount nut (3) for the left fuel tank shield.
- Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
- Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).

NOTE: Refer to Fastener Notice in Service Precautions.




13. Remove the cap from the EVAP pipe.
14. Connect the EVAP pipe (2) at the left tank EVAP pipe (1).
15. Connect the tank crossover hose (5) at the left fuel tank.
16. Push the clamp (6) outboard against the fuel tank. Keep the clamp parallel with the white stripe on the tank crossover hose.

Tighten the tank crossover hose clamp to 4 N.m (35 lb in).
17. Install the left muffler.
18. Refill the fuel system.
19. Tighten the fuel filler cap.
20. Connect the negative battery cable.
21. Inspect for leaks.
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Inspect for fuel leaks.
22. Program the transmitters. Refer to Transmitter Programming (Domestic) Transmitter Programming (Export - Including Canada) in Keyless Entry.

RIGHT FUEL TANK PIPES REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

NOTE:
- Do not repair the fuel feed or return pipes.
- Replace the fuel feed and return pipes with original equipment or with parts that meet the GM specifications for those parts. The replacement pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection.

IMPORTANT: Mark or identify each fuel pipe in order to aid in installing the pipes in their original positions.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tanks. Refer to Fuel Tank Draining Procedure.
4. Remove the left and right muffler.
5. Disconnect the tank crossover hose (5) at the right fuel tank and the left fuel tank.
6. Disconnect the EVAP pipe (2) at the right tank EVAP pipe (3) and at the left tank EVAP pipe (1).
7. Cap the open pipes in order to prevent possible contamination.




8. Disconnect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank.
9. Disconnect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.




10. Remove the right fuel tank shield mount nut (3).
11. Remove the right fuel tank shield mount bolt (2).
12. Remove the right fuel tank shield (1).




13. Remove the fuel pipes from the 2 rear upper fuel and EVAP pipe retainers (2).




14. Disconnect the auxiliary fuel return rear pipe (3) from the jet pump to the left tank.
15. Disconnect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.
16. Remove the auxiliary fuel return rear pipe from the jet pump to the left tank.
17. Remove the auxiliary fuel feed rear pipe from the left tank to the jet pump.
18. Cap the fuel sender pipes and the left tank fuel pipes.

RIGHT FUEL TANK PIPES INSTALLATION PROCEDURE




1. Install the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.

IMPORTANT: Lubricate the fuel pipes in order to aid in installation. Use mechanic's wire attached to the fuel sender end of the fuel pipe in order to pull the fuel pipe through the tunnel reinforcement opening. Pull the fuel pipe through from the top down.

2. Install the auxiliary fuel return rear pipe (3) from the jet pump to the left tank.
3. Remove the caps from the pipes.
4. Connect the auxiliary fuel return rear pipe (3) from the jet pump to the left tank.
5. Connect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.




6. Install the fuel pipes into the 2 rear upper fuel and EVAP pipe retainers (2).

Tighten the fuel and EVAP pipe retainer nuts to 3 N.m (27 lb in).




7. Connect the auxiliary fuel feed rear pipe (2) from the left tank to the jet pump.
8. Connect the auxiliary fuel return rear pipe (1) from the jet pump to the left tank.




9. Install the right fuel tank shield (1).
10. Install the right fuel tank shield mount bolt (2).
11. Install the right fuel tank shield mount nut (3).

- Tighten the fuel tank shield mount bolt to 25 N.m (18 lb ft).
- Tighten the fuel tank shield mount nut to 12 N.m (106 lb in).




12. Remove the caps from the pipes.
13. Connect the EVAP pipe (2) at the right tank EVAP pipe (3) and at the left tank EVAP pipe (1).
14. Connect the tank crossover hose (5) at the right fuel tank and at the left fuel tank.
15. Push the clamp (4) outboard against the fuel tank. Keep the clamp parallel with the white stripe on the tank crossover hose.

Tighten the tank crossover hose clamps to 4 N.m (35 lb in).

16. Install the right muffler and the left muffler.
17. Refill the fuel system.
18. Tighten the fuel filler cap.
19. Connect the negative battery cable.
20. Inspect for leaks.
1. Turn the ignition switch ON for 2 seconds.
2. Turn the ignition switch OFF for 10 seconds.
3. Turn the ignition switch ON.
4. Inspect for fuel leaks.
21. Program the transmitters. Refer to Transmitter Programming (Domestic) Transmitter Programming (Export - Including Canada) in Keyless Entry.