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Home › Saturn › 2007 › Relay 3.9 1 › Repair and Diagnosis › Engine Performance › System › Engine Controls And Fuel - Introduction (2 Of 2) › Repair Instructions › Fuel Hose/Pipes Replacement - Chassis › Removal Procedure

Removal Procedure

CAUTION: In order to Reduce the Risk of Fire and Personal Injury:
  • If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them.
  • When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible 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.
  • Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. 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.)
NOTE: Refer to NYLON FUEL LINES NOTICE .
NOTE: 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.
    Fig 1: Identifying Fuel Tank Feed Pipe Quick Connect Fitting
    GM1682041Courtesy of GENERAL MOTORS CORP.
  1. Remove the engine and transmission as an assembly. Refer to Engine Replacement .
  2. Disconnect the fuel feed (1) and evaporative emission (EVAP) (2) pipes from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
    3. Fig 2: Identifying Fuel/EVAP Pipe Clip Nut
    GM1682380Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel/EVAP pipe clip nut.
  4. Perform the following procedures if equipped with auxiliary rear air and heat.
    1. Disconnect the rear heater and A/C pipes from the rear heating, ventilation, and air conditioning (HVAC) module. Refer to Auxiliary HVAC Module Replacement .
    2. Move the rear heater and A/C pipes in order to remove the fuel pipes.
    5. Fig 3: Identifying Fuel/EVAP Pipe Clip
    GM1682383Courtesy of GENERAL MOTORS CORP.
  5. Remove the fuel/EVAP pipe clip from the stud.
    6. Fig 4: Removing/Installing Fuel/EVAP Pipe At Clips
    GM1682384Courtesy of GENERAL MOTORS CORP.
  6. Remove the fuel/EVAP pipe clips from the studs.
    7. Fig 5: View Of Fuel & EVAP Line
    GM1544726Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel and EVAP pipes (1).
  8. Inspect the pipes for bends, kinks, and cracks.
  9. Replace the pipe or pipes as required.
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