GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.2L 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the quick-connect fitting at the fuel feed line. Refer to Metal Collar Quick Connect Fitting Service .
  3. Plug the fuel lines.
  4. Remove the engine fuel feed and return pipe retainer and screws holding the fuel pipes.
  5. Remove the vacuum hose from the fuel pressure regulator.
  6. Remove the fuel return pipe retaining nut from the fuel pressure regulator using a back-up wrench.
  7. Remove the fuel pipes from fuel rail assembly.

    8. 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.

  8. 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 fuel return pipe retaining nut to 30 N·m (22 lb ft).

  4. Install the vacuum hose to the fuel pressure regulator.
  5. Install the fuel feed pipe quick connect to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .

    6. 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.

  6. Install the fuel pipe retainer screws.

    7. Tighten
    Fuel pipe retainer screws to 12 N·m (106 lb in).

  7. Install the negative battery cable.
  8. Inspect for fuel leaks through the following steps:
    9. 8.1. Turn the ignition switch to the ON position for two seconds.
    8.2. Turn the ignition switch to the OFF position for ten seconds.
    8.3. Turn the ignition switch to the ON position.
    8.4. Check for fuel leaks.