Fuel/Vapor Lines and Clips
NOTE: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.FUEL/VAPOR LINES AND CLIPS REMOVAL
1. Position vehicle on hoist.
2. Disconnect negative battery cable battery.
WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.
WARNING: Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
Fuel Guage Hook Up:
3. Release fuel pressure at valve using gage bar kit (Saturn Tool) SA9127E located on fuel delivery line at engine and install cap.
WARNING: Whenever fuel lines are removed, catch fuel in an approved container. container opening must be a minimum of 300 mm (12 in.) dia4eter to adequately catch the fluid.
Fuel Line Connections:
4. Disengage fuel lines at fuel rail or fuel filter by pinching the plastic retainer and pulling. The EVAP canister purge line is disconnected under the brake master cylinder.
NOTE: To facilitate removal, it may be necessary to spray quick connects with penetrating oil to remove debris.
WARNING: make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
5. Raise vehicle to a comfortable working position.
WARNING: Never drain or store fuel in any open container due to the possibility or fire or explosion.
Fuel Line Clips:
6. Release the seven fuel line bundle fasteners, remove stone shield, open clips and remove damaged fuel line.
7. Remove the underbody frame rail support brace.
8. Disconnect fuel and vapor lines at left front side of fuel tank.
9. Remove fuel lines from the clips at the front of fuel tank.
NOTE: Fuel lines are serviced by replacing the fuel feed assembly or the entire fuel line assembly. Individual fuel lines are not available. The fuel feed assembly consists of the fuel filter, fuel filter bracket, and fuel supply line from filter to fuel rail.
INSTALLATION
WARNING: If fuel lines were disconnected at connectors, lubricate steel line male ends with clean engine oil holding steel line, firmly press on female coupler until click is heard, then pull back to confirm engagement pinched, kinked or damaged fuel and vapor lines must be replaced.
NOTE: Plastic retainers must be replaced when fuel lines are disassembled. Install new retainer into female cavity. Care must be taken to assure 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.
NOTE: Fuel lines cannot be spliced. If damaged, they must be replaced with the same type of line.
1. Make sure lines are not kinked, bent, or damaged.
2. Install fuel and vapor hoses. Make sure the lines are properly routed. Attach the fuel line connectors at both the fuel tank and engine. Connect the vapor line at both ends.
NOTE: Pal nuts that are corroded or damaged must be replaced to ensure fuel line retainers do not come loose from the vehicle's body.
3. Clip the fuel and vapor hoses in place; install stone shield and nuts.
Torque to 3 N.m (27 in-lbs)
4. Install the underbody frame rail support brace and four fasteners.
Torque to 12 N.m (106 in-lbs)
5. Lower vehicle.
6. Connect battery negative terminal.
7. Prime fuel system.
a. Cycle ignition on for 5 seconds and then off for 10 seconds.
b. Repeat step 7a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 7a-7c.
8. Run engine and check the system for leaks.