Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
2. Clean all the fuel pipe connections and the surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel system.
3. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
4. Cap the fuel rail pipes.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
6. Remove the left hand catalytic converter. Refer to Catalytic Converter Replacement (Service and Repair).
7. Remove the fuel pipes from the bellhousing stud clip (4).
8. Remove the fuel pipes from the transmission bracket clip.




9. Disconnect the chassis fuel feed hose at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
10. Cap the rear fuel pipes.
11. Note the position of the fuel pipes for aid in installation.
12. Remove the fuel pipes from the retaining clips.
13. Remove the fuel pipes.

Installation Procedure

Important:
* When replacing the fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes in order to ensure the integrity of the connection.

* DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124-M specification or the equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required.


1. Install the fuel pipes into the retaining clips.




2. Remove the caps from the rear fuel pipes.
3. Connect the chassis fuel feed hose at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




4. Install the fuel pipes into the transmission bracket clip.
5. Install the fuel pipes into the bellhousing stud clip (4).
6. Lower the vehicle.
7. Install the left hand catalytic converter. Refer to Catalytic Converter Replacement (Service and Repair).
8. Remove the caps from the fuel rail pipes.
9. Connect the fuel feed and return pipes (1, 2) to the fuel rail.
10. Tighten the fuel filler cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Battery Negative Cable Disconnection and Connection).
12. Use the following procedure in order to inspect for leaks:

1. Turn ON the ignition, with the engine OFF, for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

13. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Upper Intake Manifold Sight Shield Replacement).