GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Monte Carlo 🢒 Engine 🢒 Engine Controls - 3.4L 🢒 Fuel Hoses/Pipes Replacement - Filter to Tank

Removal Procedure

    Object Number: 531026 Size: SH

    Notice: 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.

    Important: Always maintain cleanliness when servicing fuel system components.

  1. Remove the fuel tank. Refer to Fuel Tank Replacement .
  2. Disconnect the fuel feed, the fuel return and the evaporative emission (EVAP) pipe quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .

    3. Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

    Important: Note the position of the pipes and the attaching hardware for installation.

  3. Remove the attaching hardware from the following pipes and remove the pipes:
    4. • Fuel feed pipe
    • Fuel return pipe
    • EVAP pipe

Installation Procedure

    Object Number: 531026 Size: SH

    Caution: In order to reduce the risk of fire and personal injury observe the following items:

       • Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
       • Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a 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.
       • Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.)

    Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.

    Do not repair sections of fuel pipes.

    Notice: 

       • Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (½ inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (¾ inch) around any moving part.
       • Do not allow the fuel pipes to come into contact with the fuel tank or underbody.

    Notice: 

       • Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle.
       • Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes.
       • Replace the vapor pipes with original equipment or parts that meet GM specifications.
       • Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomer or GM 6163M on the hose.

    Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

  1. Install the following pipes and install the attaching hardware to the pipes as noted during removal:
    2. • EVAP pipe
    • Fuel return pipe
    • Fuel feed pipe
  2. Remove the caps from the fuel filter pipes and the fuel sender fuel pipes.
  3. Connect the fuel feed, the fuel return and the EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Inspect and ensure that all of the fuel pipe bundle clips and fasteners are properly installed.
  5. Install the fuel tank. Refer to Fuel Tank Replacement .