GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 SKY 🢒 Engine 🢒 Engine Controls and Fuel - 2.2L or 2.4L 🢒 Evaporative Emission Hose/Pipe Replacement - Chassis

Removal Procedure

    Object Number: 1592525 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Disconnect the evaporative emission (EVAP) pipe (1) quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  3. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  4. Cap or plug the fuel feed pipe, fuel rail and EVAP line to in order to system prevent contamination.

    5. Object Number: 1590485 Size: SH
  5. Remove the fuel feed and evaporative emission (EVAP) pipe clip from the oil level indicator tube bracket.

    6. Object Number: 1765987 Size: SH
  6. Ensure that the area around the brake pipe connections is free of dirt and/or debris.
  7. Remove the brake pipes from the brake pressure modulator valve (BPMV), if equipped.

    8. Object Number: 1765988 Size: SH
  8. Remove the brake pipes from the proportioning valve, if equipped.
  9. Cap or plug the BMPV or the proportioning valve in order to prevent system contamination.
  10. Remove the fuel tank. Refer to Fuel Tank Replacement.

    11. Object Number: 1766011 Size: SH
  11. Remove the brake hose clips (2) from both the right and left brake hose brackets.
  12. Remove the right and left brake pipes (1) from the brake hoses. (left side shown, right side similar).

    13. Object Number: 1594606 Size: SH
  13. Remove the pipe clips (1) from the following:
    14. • Rear suspension lower control arm bracket
    •  Left hand brace floor panel tunnel

    Object Number: 1765991 Size: SH
  14. Remove the pipe clips (1) from the following:
    15. • Floor panel number 4 cross bar
    • Rear carrier bracket
    • Right hand brace floor panel tunnel
  15. Remove the pipe clip (2) from the floor panel rear reinforcement.
  16. Have an assistant support the fuel feed, EVAP, and brake pipe assembly.

    17. Object Number: 1594573 Size: SH
  17. Remove the pipe clip (1) from the underbody side rail.
  18. Remove the pipe clip (2) from the floor panel tunnel brace stud.
  19. Remove the pipe clip (3) from the floor panel tunnel brace stud.
  20. Remove the pipe clips (4) from the floor panel studs.
  21. Remove the fuel feed, EVAP, and brake pipe assembly from the vehicle and place on a suitable work surface.

    22. Object Number: 1766013 Size: SH
  22. Disconnect the EVAP canister purge line (6) from the EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
  23. Remove the retaining clip (1) from the lines.
  24. Open the clips (4 and 7), and remove the EVAP line (3) from the clips.
  25. Inspect and replace and damaged clips.

Installation Procedure

    Object Number: 1766013 Size: SH
  1. Install the EVAP line (3) to the clips and close the clips (4 and 7).
  2. Install the retaining clip (1) to the lines.
  3. Connect the EVAP canister purge line (6) to the EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.

    4. Object Number: 1594573 Size: SH
  4. With the aid of an assistant, install the fuel feed, EVAP, and brake pipe assembly to the vehicle.
  5. Install the pipe clips (4) to the floor panel studs.
  6. Install the pipe clip (3) to the floor panel tunnel brace stud.
  7. Install the pipe clip (2) to the floor panel tunnel brace stud.
  8. Install the pipe clip (1) to the underbody side rail.

    9. Object Number: 1765991 Size: SH
  9. Install the pipe clip (2) to the floor panel rear reinforcement.
  10. Install the pipe clips (1) from the following:
    11. • Floor panel number 4 cross bar
    • Rear carrier bracket
    • Right hand brace floor panel tunnel

    Object Number: 1594606 Size: SH
  11. Install the pipe clips (1) to the following:
    12. • Rear suspension lower control arm bracket
    •  Left hand brace floor panel tunnel

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1766011 Size: SH
  12. Install the right and left brake pipes (1) to the brake hoses. (left side shown, right side similar).

    13. Tighten
    Tighten the pipes to 20 N·m (15 lb ft).

  13. Install the brake hose clips (2) to both the right and left brake hose brackets.

    14. Object Number: 1765988 Size: SH
  14. Install the fuel tank. Refer to Fuel Tank Replacement.
  15. Remove the cap or plug from the BMPV or the proportioning valve.
  16. Install the brake pipes to the proportioning valve, if equipped.

    17. Tighten
    Tighten the pipes to 20 N·m (15 lb ft).


    Object Number: 1765987 Size: SH
  17. Install the brake pipes to the BPMV, if equipped.

    18. Tighten
    Tighten the pipes to 20 N·m (15 lb ft).


    Object Number: 1590485 Size: SH
  18. Install the fuel feed and EVAP pipe clip to the oil level indicator tube bracket.

    19. Object Number: 1592525 Size: SH
  19. Remove the cap or plug from the fuel feed pipe, fuel rail and EVAP line.
  20. Connect the fuel feed pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  21. Connect the EVAP pipe (1) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  23. Inspect for fuel leaks using the following procedure:
    24. 23.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    23.2. Turn OFF the ignition for 10 seconds.
    23.3. Turn ON the ignition, with the engine OFF.
    23.4. Inspect for fuel leaks.