Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Special Tools
* J 34730-1A Fuel Pressure Gage
* J 37088-A Fuel Line Disconnect Tool Set

Removal Procedure




Warning: Refer to Battery Disconnect Warning (Service Precautions).

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
3. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027)).





Caution:
* 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.

4. Disconnect the fuel feed hose (2) from the chassis fuel feed pipe (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
5. Cap the engine compartment fuel feed pipe.




6. Disconnect the chassis fuel and EVAP pipe retainer (1) from the upper front of dash mounting stud (3).

Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.


7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
8. Remove the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement (Service and Repair).




9. Remove the floor panel tunnel panel reinforcement. Refer to Floor Panel Tunnel Panel Reinforcement Replacement (Service and Repair).




10. Disconnect the chassis fuel pipe (5) from the underbody retainers (6).
11. Remove the chassis fuel pipe.

Installation Procedure

Note:
* Follow the same routing as the original pipe.
* Secure the pipe in order to prevent chafing.
* Do not kink or bend the pipe.




1. Install the chassis fuel pipe (5) into the underbody retainers (6).
2. Connect the chassis fuel feed pipe.




3. Install the floor panel tunnel panel reinforcement. Refer to Floor Panel Tunnel Panel Reinforcement Replacement (Service and Repair).
4. Install the exhaust intermediate pipe. Refer to Intermediate Pipe Replacement (Service and Repair).
5. Lower the vehicle.
6. Remove the cap from the engine compartment fuel feed pipe.





Caution: Refer to Fastener Caution (Fastener Caution).

7. Connect the chassis fuel and EVAP pipe retainer (1) at the upper front of dash mounting stud (3) and tighten to 6 Nm (53 lb in).




8. Connect the fuel feed hose (2) to the chassis fuel feed pipe (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
9. Tighten the fuel filler cap.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
11. Perform the following procedure in order to 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.




12. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
13. Program the transmitters. Refer to Transmitter Programming (N. America and Japan, except Canada) (Programming and Relearning)Transmitter Programming (Canada and Europe) (Programming and Relearning)Transmitter Programming (New RCDLRs ONLY) (Programming and Relearning).