GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2003 🢒 Grand Prix 🢒 Engine 🢒 Engine Electrical 🢒 Fuel Hose/Pipes Replacement - Filter to Engine

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .

    3. Object Number: 73984 Size: SH

    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.

  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  4. Clean all engine fuel pipe connections.
  5. Clean areas surrounding the engine fuel pipe connections.
  6. Disconnect the fuel feed and fuel return pipe quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .

    7. Object Number: 669537 Size: SH
  7. Disconnect the evaporative emission (EVAP) purge pipe from the EVAP purge valve. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Remove the brake master cylinder from the brake booster and reposition. Refer to Master Cylinder Replacement in Hydraulic Brakes.
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    10. Object Number: 699549 Size: SH
  10. Disconnect the fuel return pipe quick-connect fitting and the EVAP purge pipe at the front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  11. Use a back-up wrench in order to prevent the fuel filter from turning and remove the fuel feed pipe threaded nut fitting at the outlet of the fuel filter.
  12. Cap the fuel filter and the return pipe as needed to stop any fuel leakage.

    13. Object Number: 189079 Size: SH
  13. Note the position of the fuel feed, the fuel return, the EVAP pipes and the attaching hardware for installation.
  14. Remove the fuel feed, the fuel return, and the EVAP pipe attaching hardware.
  15. Remove the fuel feed, the fuel return and the EVAP pipes from the vehicle.

    16. 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.

  16. Inspect the pipes for bends, kinks and cracks.
  17. Replace the pipe or pipes as required.

Installation Procedure

    Object Number: 189079 Size: SH

    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.)

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

  1. Install the fuel feed, the fuel return, and the EVAP pipes to the vehicle.
  2. Install the fuel feed, the fuel return, and the EVAP pipe attaching hardware as noted during removal.
  3. Remove the caps from the fuel filter and the fuel return pipe.

    4. Object Number: 699549 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.

  4. Install the fuel feed pipe threaded fitting nut to the fuel filter outlet.

    5. Tighten
    Use a back-up wrench in order to prevent the fuel filter from turning and tighten the threaded fitting nut to 30 N·m (22 lb ft).

  5. Connect the fuel return pipe quick-connect fitting and the EVAP purge pipe at the front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Verify that all of the fuel pipe bundle clips and fasteners are properly installed.
  7. Lower the vehicle.
  8. Install the brake master cylinder to the brake booster. Refer to Master Cylinder Replacement in Hydraulic Brakes.

    9. Object Number: 669537 Size: SH
  9. Connect the EVAP purge pipe to the EVAP purge valve. Refer to Plastic Collar Quick Connect Fitting Service .

    10. Object Number: 73984 Size: SH
  10. Connect the fuel feed and the fuel return pipe quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
  11. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
  12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  13. Inspect the fuel system for leaks by performing the following steps:
    14. 13.1. Turn ON the ignition for 2 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition.
    13.4. Inspect for fuel leaks.