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Home >> Saturn >> 2005 >> Relay AWD >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.5L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Hose/Pipes Replacement - Engine Compartment >> Removal Procedure
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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 in Cautions and Notices.
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.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
    3. Fig 1: View Of Fuel Hoses/Pipes
    GM1544724Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel feed pipe retaining clip (2).
  4. Disconnect the engine fuel feed pipe (3) from the fuel rail (1). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  5. Disconnect the evaporative emission (EVAP) pipe (5) from the EVAP canister purge solenoid valve (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  6. Cap the fuel pipes as needed to stop any fuel leakage.
  7. Remove the engine and transmission as an assembly. Refer to Engine Replacement in Engine Mechanical.
  8. 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 HVAC Module Replacement - Auxiliary in Heating, Ventilation and Air Conditioning.
    2. Move the rear heater and A/C pipes in order to remove the fuel pipes.
    9. Fig 2: View Of Fuel & EVAP Line
    GM1544726Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel feed and evaporative emission (EVAP) pipes from the fuel tank. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Note the position of the fuel and EVAP pipes and the attaching hardware for installation.
  11. Remove the fuel and EVAP pipes (1).
  12. Inspect the pipes for bends, kinks, and cracks.
  13. Replace the pipe or pipes as required.
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