GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Hose/Pipes Replacement - Chassis

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the pipe retaining clip (1) from the fuel feed pipe.

    3. Object Number: 879147 Size: SH
  3. Disconnect the fuel feed pipe from the engine fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  4. Cap or plug the fuel pipe and the engine fuel rail to prevent contamination.

    5. Object Number: 889727 Size: SH
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Remove the evaporative emission (EVAP) canister for pipe removal access. Refer to Evaporative Emission Canister Replacement
  7. Disconnect the fuel filter from the engine feed fuel pipe (1). Refer to Metal Collar Quick Connect Fitting Service .

    8. Object Number: 890000 Size: SH
  8. Remove the rear brake pipe bracket retaining nuts and release the brackets from the body studs.

    9. Object Number: 49888 Size: SH
  9. Release the pipe retainers (1) from the vehicle underbody.
  10. Remove the fuel feed pipe from the pipe retainers.
  11. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
  12. Remove the fuel feed pipe from the vehicle.

Installation Procedure

    Object Number: 49888 Size: SH
  1. Position the fuel feed pipe to the vehicle.
  2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
  3. Install the remainder of the pipe into position.
  4. Install the fuel feed pipe to the pipe retainers.
  5. Secure the pipe retainers (1) to the vehicle underbody.

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


    Object Number: 890000 Size: SH
  6. Install the rear brake hose brackets to the body studs and install the rear brake hose bracket retaining nuts.

    7. Tighten
    Tighten the nuts to 10 N·m (89 lb in).


    Object Number: 889728 Size: SH
  7. Connect the fuel filter to the engine feed fuel pipe (1). Refer to Metal Collar Quick Connect Fitting Service .
  8. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement
  9. Lower the vehicle.

    10. Object Number: 879147 Size: SH
  10. Remove the caps or plugs from the fuel pipe and the engine fuel rail.
  11. Connect the fuel feed pipe to the engine fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  12. Install the pipe retaining clip (1) to the fuel feed pipe.
  13. Connect the negative battery cable.
  14. Inspect for fuel leaks using the following procedure:
    15. 14.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition, with the engine OFF.
    14.4. Inspect for fuel leaks.