Fuel Pipes
REMOVAL PROCEDURE
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 at the engine compartment fuel feed and return pipes (1) and the attaching hardware (2). Be careful not to bend the fuel feed and return pipes.
4. Disconnect the fuel pipes (1) and the attaching hardware (2) at the fuel filter assembly.
5. Remove the fuel tank.
6. Refer to Fuel Tank Replacement. Procedures
7. Disconnect the fuel feed (1) and vapor (2) hoses.
8. Remove the hardware retaining section of pipe to be replaced. Note location of attaching hardware for installation.
9. Remove the section of pipe and hoses.
CLEANING AND INSPECTION PROCEDURE
NOTE: Remove rust or burrs from the engine compartment fuel pipes using the following procedure:
1. Use emery cloth in order to remove rust or burrs from a fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
2. Use a clean shop towel in order to wipe off the male tube ends.
3. Inspect all the connectors for dirt and burrs. Clean or replace the components and assemblies as required.
Steel fuel lines - These are welded steel tubes, meeting GM specifications 124-M, or its equivalent. The fuel feed line is 3/8 inches diameter and the fuel return line is 5/16 inches diameter. Do not use copper or aluminum tubing to replace steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibration.
Coupled hose - Do not repair the hoses. Replace them only as an assembly.
Uncoupled hose - Use only reinforced fuel resistant hose, made of Fluoroelastomer material. Do not use a hose within 4 inches (100 mm) of any part of the exhaust system, or within 10 inches (2154 mm) of the catalytic converter. The hoses inside diameter must match the outside diameter of the steel tubing. Clamps - These are stainless steel, screw bank-type clamps, #2494772, or equivalent.
STEEL FUEL LINE REPAIR
1. Cut a piece of fuel hose 4 inches (100 mm) longer than the section of line to be removed. If you remove more than 6 inches (152 mm), use a combination of steel pipe and hose. The hose length should not be more than 10 inches total.
2. With a tube cutter, cut a section of the pipe to replace. Use the first step on the reamer to form a bead on the ends of the pipe and, also, on the new section of pipe, if used.
3. Slide the hose clamps onto the pipe and push the hose 2 inches (51 mm) onto each portion of the fuel pipe. Tighten a clamp on each side of the repair.
4. Secure fuel line to the frame.
5. Check for leaks.
INSTALLATION PROCEDURE
CAUTION: In order to reduce the risk of fire and personal injury, 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.
1. Install the new O-rings on the engine fuel feed and return pipes.
2. Connect the fuel feed and return pipes (1) to the engine fuel pipes.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.
4. Connect the fuel pipe attaching hardware (2).
NOTE: Refer to Fastener Notice in Service Precautions.
Position the new fuel pipe harness in the original location and the fuel pipe harness attaching hardware (2), tighten to specification.
Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.
5. Remove protective caps from one end of both fuel pipes.
Leave caps on other end of pipes to prevent dirt from entering.
6. Apply a few drops of clean engine oil to the male connector tube ends.
7. Connect the quick-connect fittings at the fuel feed and return pipe near the in-line filter and at the fuel sender assembly (1) and (2). Refer to Quick Connect Fitting(s) Service (Metal Collar) and Quick Connect Fitting(s) Service (Plastic Collar). Service and Repair
8. Install the fuel tank and attaching fuel pipe hardware.
9. Tighten the fuel filler cap.
10. Connect the negative battery cable.
11. Check for fuel leaks.
11.1. Turn the ignition switch to the ON position for 2 seconds.
11.2. Turn the ignition switch to the OFF position for 10 seconds.
11.3. Again, turn the ignition switch to the ON position.
11.4. Check for fuel leaks.