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For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Bonneville 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Fuel Hose/Pipes Replacement - Filter to Engine

Fuel Hose/Pipes Replacement - Filter to Engine VIN K

Tools Required

J 34730 Fuel Pressure Gauge

Removal Procedure

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: 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.


    Object Number: 486344 Size: SH
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Clean all of the engine fuel pipe connections and the areas surrounding the connections before disconnecting the pipes in order to avoid contamination of the fuel system.
  3. Remove the fuel feed (1) and fuel return (2) quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Remove the EVAP pipe.

    5. Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  5. Raise the vehicle.

    6. Object Number: 65986 Size: SH
  6. Remove the quick-connect fittings on the engine-side of the in-line fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Cap the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to prevent any fuel leakage.
  8. Remove the following hardware and pipes:
    9. • The fuel feed pipes and hardware
    • The fuel return pipes and hardware
    • The EVAP pipes and hardware
  9. Note the position of the pipes and the attaching hardware for installation.
  10. Inspect the retainers and pipes for bends, kinks, and cracks.
  11. Repair or replace the pipes and retainers 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: 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.


    Object Number: 486344 Size: SH
  1. Install the following hardware and pipes:
    2. • The fuel feed pipes and hardware
    • The fuel return pipes and hardware
    • The EVAP pipes and hardware

    Object Number: 65986 Size: SH
  2. Remove the caps from the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
  3. Install new plastic connector retainers on the fuel pipes.
  4. Install the quick-connect fittings at the in-line fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .

    5. 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.

  5. Install the threaded nut at the in-line fuel filter.

    6. Tighten
    Tighten the nut to 30 N·m (22 ft lb).

  6. Lower the vehicle.
  7. Install the quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Add fuel to the fuel tank.
  9. Install the fuel filler cap.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
    11. 10.1. Turn ON the ignition switch for 2 seconds.
    10.2. Turn OFF the ignition switch for 10 seconds.
    10.3. Turn ON the ignition switch for 2 seconds.
    10.4. Check for fuel leaks.

Fuel Hose/Pipes Replacement - Filter to Engine VIN 1

Tools Required

    • J 34730 Fuel Pressure Gauge
    • J 37088-A Fuel Pipe Quick-Connect Separator

Removal 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: 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.

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.


    Object Number: 489615 Size: SH
  1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
  2. Clean all of the engine fuel pipe connections and the areas surrounding the connections before disconnecting the connectors to avoid contamination of the fuel system.
  3. Remove fuel line retaining clips from fuel pipes (4).
  4. Remove the fuel feed (3) and fuel return (1) quick-connect fittings from the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  5. Remove the EVAP pipe (2) from the EVAP canister purge valve.

    6. Object Number: 65986 Size: SH

    Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  6. Raise the vehicle.
  7. Remove the quick-connect fittings and the threaded nut on the engine-side of the in-line filter. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe in order to prevent any fuel leakage.
  9. Note the position of the fuel pipes and the EVAP pipes and the attaching hardware for the re-installation.

    10. Object Number: 489840 Size: SH
  10. Remove the following components:
    11. • The fuel feed pipes (3)
    • The fuel return pipes (4)
    • The EVAP pipes

    Object Number: 65808 Size: SH
  11. Inspect the retainers and the pipes for bends, kinks, and cracks.
  12. Repair or replace the pipes and retainers as necessary.

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: 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.


    Object Number: 489840 Size: SH
  1. Install the following components in the locations noted during removal:
    2. • The fuel feed pipes (3)
    • The fuel return pipes (4)
    • The EVAP pipes
  2. Remove the caps from the in-line fuel filter pipe, the fuel feed pipe, and the EVAP pipe.
  3. Install new plastic connector retainers on the fuel pipes.

    4. Object Number: 65986 Size: SH
  4. Install the quick-connect fittings at the in-line fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .

    5. 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.

  5. Install the threaded nut at the in-line fuel filter.

    6. Tighten
    Tighten the nut to 30 N·m (22 lb ft).


    Object Number: 489615 Size: SH
  6. Install the fuel line retaining clips to the fuel pipes.
  7. Lower the vehicle.
  8. Install the fuel feed (3), the fuel return (1), and the quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
  9. Install the EVAP pipe in the engine compartment.

    10. Tighten
    Tighten the attaching hardware to 12 N·m (106 in lb).

  10. Add fuel to the fuel tank.
  11. Install the fuel filler cap.
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
    13. 12.1. Turn ON the ignition switch for 2 seconds
    12.2. Turn OFF the ignition switch for 10 seconds.
    12.3. Turn ON the ignition switch.
    12.4. Check for fuel leaks.

    Object Number: 49593 Size: SH
  13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .