GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 3.1L 🢒 Fuel Hoses/Pipes Replacement - Filter to Tank

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the fuel feed pipe quick-connect fitting at the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  3. Disconnect the fuel return pipe quick-connect fitting at the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  4. Plug the fuel lines to prevent leakage.
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Disconnect the fuel feed pipe quick-connect fitting at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel return pipe quick-connect fitting at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Plug the fuel lines to prevent leakage.
  9. Remove the exhaust heat shield.

    10. Object Number: 102056 Size: SH
  10. Remove the fuel pipe mounting bolts from the body clips.

    11. Object Number: 102255 Size: SH
  11. Remove the fuel pipes from the body clips.

    12. Object Number: 49888 Size: SH
  12. Remove the fuel pipes (1) to be serviced.

Installation Procedure

    Object Number: 49888 Size: SH
  1. Install the fuel pipe (1) and hose hardware.

    2. Object Number: 102255 Size: SH
  2. Position the fuel pipe in the body clips.

    3. Object Number: 102056 Size: SH

    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 pipe mounting bolts into the body clips.

    4. Tighten
    Tighten the bolts to 6 N·m (40 lb in).

  4. Install the exhaust heat shield.

    5. Tighten

        • Tighten the exhaust shield bolt to 2 N·m (18 lb in).
        • Tighten the exhaust shield nuts to 1 N·m (9 lb in).
  5. Remove the caps on the fuel lines.
  6. Connect the fuel feed pipe quick-connect fitting at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Connect the fuel return pipe quick-connect fitting at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Lower the vehicle.
  9. Remove the caps on the fuel lines.
  10. Connect the fuel feed pipe quick-connect fitting at the engine compartment Refer to Plastic Collar Quick Connect Fitting Service .
  11. Connect the fuel return pipe quick-connect fitting at the engine compartment Refer to Metal Collar Quick Connect Fitting Service .
  12. Tighten the fuel filler cap.
  13. Reconnect the negative battery cable.
  14. Inspect for fuel leaks using the following procedure:
    15. 14.1. Turn ON the ignition for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition.
    14.4. Inspect for fuel leaks.