GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis

Removal Procedure

    Object Number: 893318 Size: SH

    Caution: Ensure that the 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 the components are being removed.

    Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

  1. Position on the hoist.

    2. Object Number: 885839 Size: SH

    Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

  2. Disconnect the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

    3. Object Number: 892343 Size: SH

    Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

  3. Relieve the fuel system pressure. Refer to Fuel System Diagnosis .
  4. Raise the vehicle to a comfortable working height.

    5. Object Number: 885839 Size: SH

    Important: To facilitate the removal, it may be necessary to spray quick connects with penetrating oil to remove debris.

  5. Remove the stone chip guard.

    6. Object Number: 892344 Size: SH
  6. Disengage the chassis fuel feed, return, and evaporative emission (EVAP) canister purge lines from the front fuel feed, return, and EVAP canister purge lines located near passenger front wheel well.
  7. Disengage the fuel feed, after the fuel filter, return, and EVAP canister purge line at the fuel tank.
  8. Release the fuel line bundle from the underbody plastic retainers.
  9. Remove the damaged fuel line.

Installation Procedure

    Object Number: 892343 Size: SH

    Notice: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure 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. Pinched, kinked, or damaged fuel lines must be replaced.

    Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

  1. Make sure lines are not kinked, bent, or damaged.
  2. Install the fuel and vapor hoses. Make sure the lines are properly routed.
  3. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.

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


    Object Number: 885839 Size: SH
  4. Install the stone chip guard.

    5. Tighten
    Tighten the fuel line stone chip guard to 12 N·m (106 lb in).

  5. Install the underbody retaining clips. Hammer in place using a rubber mallet.

    6. Object Number: 892344 Size: SH
  6. Lower the vehicle.
  7. Connect the negative battery terminal.

    8. Tighten
    Tighten the battery terminal bolts to 17 N·m (13 lb ft).

  8. Prime the fuel system.
    9. 8.1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    8.2. Repeat step 8.1 twice.
    8.3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    8.4. If the engine does not start, repeat steps 8.1-8.4.
  9. Run the engine and check the system for leaks.