GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Astro - 2WD 🢒 Engine 🢒 Engine Controls - 4.3L 🢒 Fuel Hose/Pipes Replacement - Chassis

Fuel Hose/Pipes Replacement - Chassis Front

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  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. Object Number: 595537 Size: SH
  3. Disconnect the fuel feed and return pipes (8) from the engine compartment fuel pipes.
  4. Cap the engine compartment fuel pipes.
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Remove the fuel pipes retainer mounting stud (7) from the cylinder head.
  7. Remove the fuel pipes retainer mounting stud (6) from the transmission.
  8. Remove the fuel pipes retainer mounting fastener (5) from the crossrail.

    9. Object Number: 712757 Size: SH
  9. Disconnect the fuel return pipe (2) at the coupler (3).
  10. Disconnect the fuel feed pipe at the fuel filter outlet.
  11. Cap the rear fuel pipes.
  12. Note the position of the fuel pipes for aid in installation.
  13. Remove the fuel pipes from the retaining clips.
  14. Remove the fuel pipes.

Installation Procedure

    Object Number: 712757 Size: SH

    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 its equivalent is capable of meeting all pressure, corrosion and vibration characteristics necessary to ensure the durability standard required.

  1. Remove the caps from the rear fuel pipes.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Connect the chassis fuel feed pipe at the fuel filter outlet.

    3. Tighten
    Tighten the fuel feed pipe fitting to 30 N·m (22 lb ft).

  3. Connect the fuel return pipe (2) at the coupler (3).

    4. Tighten
    Tighten the return pipe fitting to 27 N·m (20 lb ft).


    Object Number: 595537 Size: SH
  4. Install the fuel pipes into the transmission bracket retainer.
  5. Install the mounting stud (6).

    6. Tighten
    Tighten the mounting stud to 33 N·m (24 lb ft).

  6. Install the fuel pipes into the cylinder head retainer.
  7. Install the mounting stud (7).

    8. Tighten
    Tighten the mounting stud to 33 N·m (24 lb ft).

  8. Install the fuel pipes into the crossrail retainer.
  9. Install the mounting bolt (5) to the crossrail.

    10. Tighten
    Tighten the mounting bolt to 11 N·m (97 lb in).

  10. Lower the vehicle.
  11. Remove the caps from the engine compartment fuel pipes.
  12. Connect the fuel feed and return pipes (8) to the engine compartment fuel pipes.

    13. Ensure the O-rings are in place.

    Tighten
    Tighten the fuel feed and return pipe fittings to 30 N·m (22 lb ft).

  13. Connect the negative battery cable.
  14. Inspect for leaks.
    15. 14.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition, with the engine OFF.
    14.4. Inspect for fuel leaks.
  15. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.

Fuel Hose/Pipes Replacement - Chassis Rear

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Object Number: 595537 Size: SH
  2. Disconnect the front fuel pipes (3) from the rear chassis pipes (1).
  3. Drain gasoline into an approved container.

    4. Object Number: 712757 Size: SH
  4. Disconnect the fuel feed pipe (1) from the fuel filter.
  5. Discard the O-ring.
  6. Disconnect the fuel return pipe (2) from the coupler (3).
  7. Discard the O-ring.

    8. Object Number: 758077 Size: SH
  8. Disconnect the fuel return (5) and the fuel feed (2) pipes from the fuel tank pipes (1).
  9. Release the fuel pipe grommet (4) from the crossrail.
  10. Remove the fuel pipe retainer (3) from the crossrail.
  11. Release the fuel pipes from the retainer and the grommet.

Installation Procedure

    Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. 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. Position the fuel pipes into the crossrail retainer and the crossrail grommet.
  3. Position the new fuel pipes through the crossrails in the original location.

    4. Object Number: 712757 Size: SH
  4. Loosely assemble the fuel feed pipe (1) to the fuel filter.
  5. Loosely assemble the fuel return pipe (2) to the coupler (3).

    6. Object Number: 758077 Size: SH
  6. Install the fuel pipe grommet (4) into the crossrail. Lubricate the grommet to aid in the installation.

    7. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  7. Install the fuel pipe retainer to the crossrail.

    8. Tighten

        • Tighten the fuel pipe crossrail retainer to 11 N·m (97 lb in).
        • Tighten the fuel feed pipe to fuel filter fitting to 27 N·m (20 lb ft) using a back-up wrench.
        • Tighten the fuel return pipe to coupler fitting to 27 N·m (20 lb ft) using a back-up wrench.
  8. Apply a few drops of clean engine oil to the rear male connector pipe ends.
  9. Connect the fuel return (5) and the fuel feed (2) pipes to the fuel tank pipes (1).
  10. Connect the negative battery cable.
  11. Inspect for fuel leaks.
    12. 11.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    11.2. Turn OFF the ignition for 10 seconds.
    11.3. Turn ON the ignition, with the engine OFF.
    11.4. Inspect for fuel leaks.
  12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.