GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Grand Prix 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Hoses/Pipes Replacement - Filter to Tank

Removal Procedure

    Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

    Important: Always maintain cleanliness when servicing the fuel system components.

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the fuel tank. Refer to Fuel Tank Replacement .

    5. Object Number: 32153 Size: SH
  5. Remove the fuel feed, the fuel return, and the evaporative emissions (EVAP) pipe quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
  6. Cap the fuel sender fuel pipes and cap the in-pipe fuel filter pipes as needed in order to stop any fuel leakage.
  7. Remove the fuel feed, the fuel return, and the EVAP pipe attaching hardware.
  8. Disconnect the fuel feed, the fuel return, and the EVAP pipes.
  9. Note the position of the fuel, the EVAP pipes, and the fuel and EVAP pipe attaching hardware for installation.

Installation Procedure

    Caution: In order to reduce the risk of fire and personal injury observe the following items:

       • Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
       • Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.
       • Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
       • Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.)

    Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

    Do not repair sections of fuel pipes.

    Notice: 

       • Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (½ inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (¾ inch) around any moving part.
       • Do not allow the fuel pipes to come into contact with the fuel tank or underbody.

  1. Install the new fuel feed, the fuel return, the EVAP pipes, and the fuel and EVAP pipe attaching hardware as noted during removal.
  2. Remove the caps from the in-pipe fuel filter pipes and from the fuel sender fuel pipes.

    3. Object Number: 32153 Size: SH

    Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

  3. Install the fuel feed, the fuel return, and the EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
  4. Inspect and ensure that all of the fuel pipe bundle clips and fasteners are properly installed.
  5. Install the fuel tank. Refer to Fuel Tank Replacement .
  6. Lower the vehicle.
  7. Add the fuel, and reinstall the fuel tank filler pipe cap.
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  9. Use the following procedure in order to inspect for leaks:
    10. 9.1. Turn ON the ignition, for 2 seconds.
    9.2. Turn OFF the ignition, for 10 seconds.
    9.3. Turn ON the ignition.
    9.4. Inspect for fuel leaks.