GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Aztek - FWD 🢒 Engine 🢒 Engine Cooling 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure

    Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel feed pipe or the engine fuel return pipe.

  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.

    3. Object Number: 49740 Size: SH
  3. Disconnect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
  5. Remove the upper intake manifold assembly. Refer to Upper Intake Manifold Replacement in Engine Mechanical.

    6. Object Number: 22507 Size: SH
  6. Disconnect the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.

    7. Object Number: 22505 Size: SH
  7. Disconnect the engine fuel feed pipe from the fuel rail. Discard the O-ring.

Installation Procedure

    Object Number: 22507 Size: SH
  1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.

    2. Object Number: 22505 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.

  2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

    3. Tighten
    Tighten the engine fuel pipe fittings to 17 N·m (13 lb ft).


    Object Number: 49740 Size: SH
  3. Reinstall the upper intake manifold assembly. Refer to Upper Intake Manifold Replacement in Engine Mechanical.
  4. Connect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  5. Tighten the fuel fill cap.
  6. Inspect for fuel leaks with the following procedure:
    7. 6.1. Turn ON the ignition for 2 seconds.
    6.2. Turn OFF the ignition for 10 seconds.
    6.3. Turn ON the ignition.
    6.4. Inspect for fuel leaks.