GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2000 🢒 Regal 🢒 General Information 🢒 General Information 🢒 Fuel Hoses/Pipes Replacement - Filter to Tank

Removal 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: 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.

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.

Notice: Replace the EVAP pipes and hoses with the original equipment or parts that meet the GM specifications for those parts. The replacement EVAP pipe must have the same type of fittings as the original pipe in order to ensure the integrity of the connection. When replacing EVAP hoses, use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163-M on the hose. The inside hose diameter must match the outside pipe diameter. Do not use rubber hose within 100 mm (4 in) of any part of the exhaust system or within 254 mm (10 in) of the catalytic converter.

Important: Always maintain cleanliness when servicing Fuel System components.

  1. Relieve the Fuel System fuel pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the fuel tank. Refer to Fuel Sender Assembly Replacement .

    5. Object Number: 32153 Size: SH
  5. Disconnect the fuel feed, fuel return, and 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 the in-pipe fuel filter pipes as needed to stop any fuel leakage.
  7. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware.
  8. Remove the fuel feed, fuel return, and EVAP pipes.
  9. Note the position of the fuel and 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, fuel return, and 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 the fuel sender fuel pipes.

    3. Object Number: 32153 Size: SH
  3. Connect the fuel feed, fuel return, and EVAP pipe quick connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
  4. Inspect and make sure 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 fuel and install the fuel tank filler pipe cap.
  8. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  9. 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. Check fuel leaks.
  10. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.