GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2001 🢒 Aztek - FWD 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 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: 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: 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.

    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.

  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Clean all engine fuel pipe connections.
  3. Clean areas surrounding the engine fuel pipe connections.

    4. Object Number: 49740 Size: SH
  4. Disconnect the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    6. Object Number: 670056 Size: SH
  6. Disconnect the fuel return pipe quick-connect fitting near in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel feed pipe quick-connect fitting on the engine-side of the in-pipe fuel filter (2). Refer to Plastic Collar Quick Connect Fitting Service .
  8. Disconnect the evaporative emission (EVAP) pipe quick-connect fitting near in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.

    10. Object Number: 670063 Size: SH
  10. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware, and the fuel feed, fuel return, and EVAP pipes.
  11. Note the position of the fuel and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation.
  12. Inspect the pipes for bends, kinks, and cracks.
  13. Replace the pipe or pipes as required.

Installation Procedure

    Object Number: 670063 Size: SH

    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.

  1. Install the new fuel feed, fuel return, and EVAP pipes and attaching hardware as noted during removal.

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

  2. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.

    3. Object Number: 670056 Size: SH
  3. Connect the EVAP pipe quick-connect fitting near the in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Connect the fuel return pipe quick-connect fitting near in-pipe fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Connect the fuel feed pipe quick-connect fitting at the outlet of the in-pipe fuel filter (2). Refer to Plastic Collar Quick Connect Fitting Service .
  6. Lower the vehicle.

    7. Object Number: 49740 Size: SH
  7. Connect the fuel feed and fuel return pipe quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Inspect the fuel pipe clips and fasteners for proper installation.
  9. Lower the vehicle.
  10. Tighten the fuel fill cap.
  11. Reconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  12. Inspect for fuel leaks with the following procedure:
    13. 12.1. Turn ON the ignition for 2 seconds.
    12.2. Turn OFF the ignition for 10 seconds.
    12.3. Turn ON the ignition.
    12.4. Inspect for fuel leaks.