GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Controls - 3.0L (L81) 🢒 Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

    Caution: Refer to Vehicle Lifting Caution in the Preface section.


    Object Number: 894302 Size: SH

    Important: Fuel/vapor lines can not be spliced or repaired. The line must be replaced, if damaged, with the same type of line.

  1. Position on a hoist.

    2. Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

    Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 892343 Size: SH
  2. Disconnect the negative battery terminal.
  3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  4. Raise the vehicle to a comfortable working height.

    5. Object Number: 885839 Size: SH
  5. Remove the stone chip guard.

    6. Object Number: 892344 Size: SH

    Important: To facilitate the removal, it may be necessary to spray quick connects with penetrating oil to remove debris.

  6. Disengage the chassis fuel feed, return, and EVAP canister purge lines from the front fuel feed, return, and EVAP canister purge lines, located near passenger's front wheel well.
  7. Disengage the fuel feed, after the fuel filter, return, and EVAP canister purge line at the fuel tank.
  8. Release the fuel line bundle from the underbody plastic retainers.
  9. Remove the damaged fuel line.

Installation Procedure

    Object Number: 892343 Size: SH

    Important: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

    Important: Fuel/vapor lines can not be spliced or repaired. The line must be replaced, if damaged, with the same type of line.

  1. Make sure the lines are not kinked, bent, or damaged.
  2. Install the fuel and vapor hoses. Make sure the lines are properly routed.
  3. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 885839 Size: SH
  4. Install the stone chip guard.

    5. Tighten
    Tighten the fuel line stone chip guard to 12 N·m (106 lb in).

  5. Install the underbody retaining clips. Hammer in place using a rubber mallet.

    6. Object Number: 892344 Size: SH
  6. Lower the vehicle.
  7. Connect the negative battery terminal.

    8. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  8. Prime the fuel system.
    9. 8.1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    8.2. Repeat step 7.1 twice.
    8.3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    8.4. If the engine does not start, repeat steps 7.1-7.4.
  9. Run the engine and check the system for leaks.