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Home >> Chevrolet >> 2005 >> Astro Van Cargo, AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - (Introduction) Specifications & Repair Instructions >> Repair Instructions >> Fuel Hose/Pipes Replacement - Chassis (Rear) >> Installation Procedure

Installation Procedure

    CAUTION: Refer to Fuel Pipe Fitting Caution in Cautions and Notices.
  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. Fig 1: Identifying Fuel Filter Pipes
    GM712757Courtesy of GENERAL MOTORS CORP.
  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. Fig 2: View Of Fuel Feed/Return Pipes
    GM758077Courtesy of GENERAL MOTORS CORP.
  6. Install the fuel pipe grommet (4) into the crossrail. Lubricate the grommet to aid in the installation.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the fuel pipe retainer to the crossrail.

    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.
    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.
  12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
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