GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Impala 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Hose/Pipes Replacement - Filter to Engine

Removal Procedure

Tool Required

J 37088-A tool set, Fuel Pipe Quick-Connect Separator

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.


    Object Number: 32409 Size: SH
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Clean all engine fuel pipe connections.
  3. Clean areas surrounding the engine fuel pipe connections.
  4. Remove the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .

    5. Object Number: 32189 Size: SH
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Disconnect the fuel return pipe quick-connect fitting in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel feed pipe threaded fitting on the engine-side of the in-pipe fuel filter.
  8. Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
  9. Remove the fuel feed, fuel return, EVAP pipe attaching hardware.
  10. Note the position of the fuel and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation.
  11. Inspect the pipes for bends, kinks and cracks.
  12. Repair or replace the pipe or pipes as required.

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: 

   • 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.

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

Do not repair sections of fuel pipes.


    Object Number: 32189 Size: SH
  1. Install the new fuel feed, fuel return, and EVAP pipes and the fuel and EVAP pipe attaching hardware as noted during removal.

    2. Important: If fuel line bundle attaching hardware is damaged or broken replace it.

  2. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
  3. Connect the fuel return pipe quick-connect fitting in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .

    4. 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.

  4. Connect the fuel feed pipe threaded fitting at the outlet of the in pipe fuel filter.

    5. Tighten
    Tighten The in-pipe fuel filter fitting to 30 N·m (22 lb ft).


    Object Number: 189079 Size: SH
  5. Inspect and make sure all of the fuel pipe bundle clips, and fasteners are properly installed.
  6. Lower the vehicle.

    7. Object Number: 32409 Size: SH
  7. Connect the fuel feed (1), and fuel return pipe (2) quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Tighten the fuel fill cap.
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  10. Inspect for leaks.
    11. 10.1. Turn ON the ignition for 2 seconds.
    10.2. Turn OFF the ignition for 10 seconds.
    10.3. Turn ON the ignition.
    10.4. Inspect for fuel leaks.
  11. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical.