GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2000 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

    Object Number: 893318 Size: SH

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

    Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

  1. Position on hoist.

    2. Object Number: 885839 Size: SH

    Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  2. Disconnect negative battery terminal.

    3. Object Number: 892343 Size: SH

    Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

  3. Relieve fuel system pressure. (Refer to "Fuel System Pressure Relief" in this section.)
  4. Raise vehicle to a comfortable working height.

    5. Important: To facilitate removal, it may be necessary to spray quick connects with penetrating oil to remove debris.

  5. Remove stone chip guard.

    6. Object Number: 892344 Size: SH
  6. Disengage chassis fuel feed, return and EVAP canister purge lines from front fuel feed, return and EVAP canister purge lines (located near passenger's front wheel well).
  7. Disengage fuel feed (after fuel filter), return and EVAP canister purge line at fuel tank.
  8. Release fuel line bundle from underbody plastic retainers.
  9. Remove damaged fuel line.

Installation Procedure

    Object Number: 892343 Size: SH

    Important: Plastic retainers must be replaced when fuel lines are disassembled. Install new retainer into female cavity. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement.

    Notice: Fuel lines cannot be spliced. If damaged, they must be replaced with the same type of line.

  1. Make sure lines are not kinked, bent, or damaged.
  2. Install fuel and vapor hoses. Make sure the lines are properly routed. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.
  3. Install stone chip guard.

    4. Tighten
    Tighten the fuel line stone chip guard to 12 N·m (106 in lb).


    Object Number: 885839 Size: SH
  4. Install underbody retaining clips. Hammer in place using a rubber mallet.

    5. Object Number: 892344 Size: SH
  5. Lower vehicle.
  6. Connect negative battery terminal.
  7. Prime fuel system.
    8. • Cycle ignition On for 5 seconds and then Off for 10 seconds.
    • Repeat step 7.1 twice.
    • Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
    • If engine does not start, repeat steps 7.1-7.4.
    • Run engine and check the system for leaks.