GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  3. Plug the fuel lines.
  4. Remove the engine fuel feed and return pipe retainer and screws.
  5. Remove the fuel return pipe from the fuel pressure regulator using a back-up wrench.
  6. Remove the fuel pipe from fuel rail.

    7. Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

  7. Discard O-rings.

Installation Procedure
  1. Remove the plugs on the fuel pipes.
  2. Install the new O-rings.

    3. 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.

  3. Install the fuel return pipe to the fuel pressure regulator.

    4. Tighten
    Tighten the retainer screw to the regulator to 6 N·m (53 lbs in).

    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.

  4. Install the fuel feed pipe to the fuel rail using a back-up wrench.

    5. Tighten
    Tighten the fuel fitting to 30 N·m (22 lbs ft).

  5. Install the quick-connect fittings. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  6. Install the fuel line retainer.

    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 line clamp screws.

    8. Tighten
    Fuel line clamp screws to 12 N·m ( 106 lbs in).

  8. Install the negative battery cable.
  9. Inspect for fuel leaks through the following steps:
    10. 9.1. Turn the ignition switch to the ON position for two seconds.
    9.2. Turn the ignition switch to the OFF position for ten seconds.
    9.3. Turn the ignition switch to the ON position.
    9.4. Check for fuel leaks.