GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Buick 🢒 2003 🢒 Regal 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Hose/Pipes Replacement - Filter to Engine

Removal Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

   • If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them.
   • When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible 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.
   • Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. 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: 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 fuel system components.


    Object Number: 73984 Size: SH
  1. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  2. Remove the brake master cylinder from the brake booster and reposition. Refer to Master Cylinder Replacement in Hydraulic Brakes.
  3. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  4. Clean all the engine fuel pipe connections.
  5. Clean areas surrounding the engine fuel pipe connections.
  6. Disconnect the fuel feed and the fuel return pipe quick-connect fitting in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the evaporative emissions (EVAP) purge pipe quick-connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    9. Object Number: 699549 Size: SH
  9. Disconnect the fuel return and the EVAP pipe quick-connect fittings in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Remove the threaded nut fitting from the outlet of the in-line fuel filter.
  11. Cap the in-pipe fuel filter, the fuel feed pipe, and the fuel return pipes as needed to stop any fuel leakage.

    12. Object Number: 189079 Size: SH
  12. Note the position of the fuel feed, the fuel return, the EVAP purge pipe and the attaching hardware for installation.
  13. Remove the fuel and the EVAP pipe clips from the pipes.
  14. Remove the fuel feed, the fuel return and the EVAP pipes from the vehicle.
  15. Inspect the pipes for bends, kinks and cracks.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

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.

Important: If fuel line bundle attaching hardware is damaged or broken, replace the hardware.


    Object Number: 189079 Size: SH
  1. Install the fuel feed, the fuel return and the EVAP pipes to the vehicle.
  2. Install the fuel and the EVAP pipe clips to the pipes.

    3. Object Number: 699549 Size: SH
  3. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipes.
  4. Connect the fuel return and the EVAP pipe quick-connect fittings in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .

    5. Notice: Refer to Fastener Notice in the Preface section.

  5. Install the fuel feed pipe threaded nut fitting at the outlet of the in-pipe fuel filter.

    6. Tighten
    Use a back-up wrench in order to prevent the in-line fuel filter outlet nut from turning. Tighten the threaded nut fitting to 30 N·m (22 lb ft).

  6. Lower the vehicle.

    7. Object Number: 73984 Size: SH
  7. Connect the EVAP purge pipe quick-connect fitting. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Connect the fuel feed and the fuel return pipe quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service .
  9. Inspect and make sure all of the fuel pipe bundle clips and fasteners are properly installed.
  10. Install the brake master cylinder to the brake booster. Refer to Master Cylinder Replacement in Hydraulic Brakes.
  11. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  12. Add fuel and Install the fuel tank filler pipe cap.
  13. Lower the vehicle.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  15. Inspect for leaks.
    16. 15.1. Turn ON the ignition for 2 seconds.
    15.2. Turn OFF the ignition for 10 seconds.
    15.3. Turn ON the ignition.
    15.4. Inspect for fuel leaks.