Mechanics

CHEVY SMELL GAS FUMES FROM OUTSIDE CAR

1992 Chevrolet Corsica

Smells problem
1992 Chevy Corsica 6 cyl Front Wheel Drive Automatic 92000 miles

I smelt gas and burning rubber outside of my car. I brought it to Monro and they said I needed to replace both fuel lines on my car and that it was a days worth of labor and it would cost $400-$450.

The return one, (I believe), is made out of metal and is rusting and is leaking alittle, the send one is rubber and is sitting on my muffler (so in conclusion, I have gas leaking on my muffler and the other fuel line, safe, right?).

I don't have $450 to fix my car. I need to know how hard it is to put a fuel line in (with no lift, practically no tools, and some idea of what I am doing, and a rusted out car bottom), if I should replace the lines with metal or rubber, or if I should just have a mechanic do it.

Any replies are greatly appreicated.
Avatar
KLynnM333
September 24, 2008.




CHASSIS TO FUEL SENDER PIPE/HOSE ASSEMBLIES

CAUTION: To Reduce the Risk of Fire and Personal injury, DO NOT attempt to repair sections of fuel pipes. If damaged, replace.

NOTE: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

REMOVE OR DISCONNECT:

Negative battery cable.
Relieve fuel system pressure.
Drain fuel tank.
Fuel tank.
Locate tank in a suitable work area away from heat, flame or other source of ignition.
Quick-connect fittings at fuel sender feed and return pipes: Grasp fuel sender feed tube and fuel feed pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn, in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn, when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Squeeze plastic tabs of male end connector and pull connection apart. Repeat for other fitting. NOTE: If it is necessary to remove rust or burrs from the fuel sender pipes: use emery cloth in a radial motion with the tube end to prevent damage to O-ring sealing surface. Using a clean shop towel, wipe off male tube ends. Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required.
Retaining clip from vapor pipe and fuel feed and return pipe/hose assemblies. Note position of retaining clip for installation.
Vapor pipe from insulator clips (2). Note position of vent pipe for installation.
Insulation clips (2) and chassis to fuel sender feed and return pipe/hose assemblies from fuel tank.
Desired chassis to fuel sender pipe/hose assembly to be replaced from insulation clips (2). Note position of chassis to fuel sender pipe assembly to be replaced for installation.
INSTALL:

CAUTION: To Reduce the Risk of Fire and Personal Injury: Before connecting fuel line fittings, always apply a few drops of clean engine oil to the male tube 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.) DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

Position new chassis to fuel sender pipe/hose assembly on insulator clips (2) as noted during removal.
Insulator clips (2) and chassis to fuel sender feed and return pipe/hose assemblies on fuel tank.
Position vapor pipe on insulator clips (2) as noted during removal.
Install retaining clip on vapor pipe and chassis to fuel sender feed and return pipe/hose assemblies as noted during removal.
Chassis to fuel sender feed and return pipe/hose assemblies quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/ringers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Fuel tank.
Add fuel and install fuel filler cap.
Negative battery cable.
Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.
Perform the "Idle Learn Procedure." The ECM will need to relearn the IAC valve pintle position following battery reconnect.
CHASSIS FUEL PIPES:

NOTE: When replacing fuel pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. The replacement pipes must have the same type of fittings as the original pipes to ensure the integrity of the connection. DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124M specification or its equivalent is capable of meeting all pressure and vibration characteristics necessary to ensure the durability standard required.

When replacing fuel hoses or repairing fuel pipes with hoses, always replace them with original equipment or parts meeting GM specifications, use only reinforced fuel-resistant hose which is identified with the word "Fluoroelastomer" or "GM 6163-M" on the hose. Inside hose diameter must match outside pipe diameter. DO NOT use rubber hose within 100 mm (4") of any part of the exhaust system or within 254 mm (10") of the catalytic converter. A minimum of 13 mm (1/2") clearance must be maintained around sharp edges such as flanges, pinch welds, etc., to prevent contact and chaffering, A minimum of 19 mm (3/4") clearance must be 4 maintained around all moving parts.

REMOVE OR DISCONNECT:

Relieve fuel system pressure.
Quick-connect fittings at engine fuel pipes: Grasp chassis feed pipe and engine compartment connecting fuel feed pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Choose correct tool from separator set J37088-A for size of fitting. Insert tool into female end of connector, push inward and pull connection apart. Repeat for other fitting.
Hydraulic modulator assembly (Vehicles equipped with Antilock Brake System Only).
Chassis fuel feed and return pipe assemblies from engine compartment connecting fuel feed and return pipes quick-connect fittings: Grasp engine compartment connecting feed pipe and chassis fuel feed pipe quick-connect fitting. Twist quick-connect fitting 41 turn in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Choose correct tool from separator set J37088-A for size of fitting. Insert tool into female end of connector, push inward and pull connection apart. Repeat for other fitting.
Raise vehicle.
Chassis fuel feed pipe from outlet side of in-line fuel filter.
Chassis fuel return pipe from chassis to fuel sender return pipe/hose quick-connect fittings: Grasp chassis fuel return pipe and chassis to fuel sender connecting pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within quick connect fitting. CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fitting: Squeeze plastic tabs of male end connector and pull connection apart. NOTE: If it is necessary to remove rust or burrs from the fuel sender pipes: use emery cloth in a radial motion with the tube end to prevent damage to O-ring sealing surface. Using a clean shop towel, wipe off male tube ends. Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required.
Body clip attaching screws (4), body clips (4), vapor pipe and fuel feed and return pipes from under body.
Vapor pipe and fuel feed and return pipe coupler. Note position of coupler for installation.
Desired pipe to be replaced or repaired from body clips (4). Note position of fuel pipe to be removed for installation.
Pipes for bends, kinks and cracks. Repair or replace pipe or pipes as required. In the repairable areas, cut a piece of fuel hose 100 mm (4") longer than portion of the pipe removed. If more than a 152 mm (6") length of pipe is removed, use a combination of steel pipe and hose so that the total hose lengths, including the 100 mm (4") additional length will not be more than 254 mm (10") long.
INSTALL OR CONNECT:

Position new or repaired fuel pipe or pipes in body clips (4), as noted during removal.
Position coupler on vapor pipe and fuel feed and return pipes as noted during removal.
Vapor pipe and fuel feed and return pipes on under body with body clips (4) and attaching screws (4).
Fuel chassis return pipe to chassis to sender connecting fuel return pipe assembly quick-connect:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/fingers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Chassis fuel feed pipe to outlet side of in-line fuel filter. Tighten Chassis fuel feed pipe fitting to 30 Nm (22 ft lb).
Lower vehicle.
Engine compartment connecting fuel feed and return pipes to chassis fuel feed and return pipe quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/ringers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Hydraulic modulator assembly (Vehicles equipped with Antilock Brake System Only).
Engine compartment connecting fuel feed and return pipe to engine fuel feed and return pipes.
Quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/fingers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Tighten fuel filler cap.
Negative battery cable.
Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.
Perform the "Idle Learn Procedure." The ECM will need to relearn the IAC valve pintle position following battery reconnect.
ENGINE COMPARTMENT CONNECTING HOSES:

Tool Required: J 37088-A Fuel Line Separator Set.

CAUTION: To Reduce the Risk of Fire and Personal Injury:
DO NOT attempt to repair sections of nylon pipes. If damaged, replace.
Identify inlet and outlet of engine, compartment connection pipes, The fuel pipes have formed bends and can only be installed in one direction. If direction is reversed, chafing may result in a fuel leak.

NOTE: If nylon fuel feed or return pipes become kinked, and cannot be straightened, they must be replaced.

REMOVE OR DISCONNECT:

Relieve fuel system pressure.
Quick-connect fittings at engine fuel pipes: Grasp chassis feed pipe and engine compartment connecting fuel return pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn, when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Choose correct tool from separator set J37088-A for size of fitting. Insert tool into female end of connector, push inward and pull connection apart. Repeat for other fitting.
Hydraulic modulator assembly (Vehicles equipped with Antilock Brake System Only).
Quick-connect fittings at chassis fuel pipes: Grasp chassis feed pipe and engine compartment connecting fuel feed pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Choose correct tool from separator set J 3T088-A for size of fitting. Insert tool into female end of connector, push inward and pull connection apart. Repeat for other fitting.
INSTALL OR CONNECT:

CAUTION: To Reduce the Risk of Fire and Personal Injury: Before connecting fuel line fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper re-connection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper re-connection if not lubricated.) DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

Engine compartment connecting fuel feed and return hose assemblies to chassis fuel feed and return pipes.
Quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/fingers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting
Hydraulic modulator assembly (Vehicles equipped with Antilock Brake System Only).
Engine compartment connection, fuel feed and return pipe to engine fuel feed and return pipes.
Quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/fingers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Tighten fuel filler cap.
Negative battery cable.
Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.
Perform the "Idle Learn Procedure." The ECM will need to relearn the IAC valve pintle position following battery reconnect.
ENGINE FUEL PIPES:

Tool Required: J 37088-A Fuel Line Separator Set.

NOTE: DO NOT attempt to repair sections of engine fuel pipe assemblies. If damaged, replace.

Relieve fuel system pressure.
Quick-connect fittings at engine fuel feed and return pipes: Grasp engine fuel feed pipe and engine compartment connecting fuel feed pipe quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within quick-connect fitting. Repeat for other fitting. CAUTION: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Using compressed air, blow out dirt from quick-connect fittings.
Quick-connect fittings: Choose correct tool from separator set J37088-A for size of fitting. Insert tool into female end of connector, push inward and pull connection apart. Repeat for other fitting.
Air duct from throttle body.
Vacuum hose from plenum.
Engine fuel feed and return pipes mounting clamp and attaching screw.
Engine fuel feed pipe from fuel rail. Discard O-ring.
Engine fuel return pipe from fuel rail. Discard O-ring.
INSTALL OR CONNECT:

New O-rings on engine fuel feed and return pipes.
Position engine fuel feed and return pipes to fuel rail and regulator. Finger tighten only.
Engine fuel feed and return pipes to engine compartment connecting fuel feed and return pipe Quick-connect fittings:
Apply a few drops of clean engine oil to the male tube ends.
Push connectors together to cause the retaining tabs/fingers to snap into place.
Once installed, pull on both ends of each connection to make sure they are secure.
Repeat for other fitting.
Engine fuel feed and return pipes mounting clamp and attaching screw. Tighten engine fuel pipe fittings to 3O Nm (22 ft lb). Tighten engine fuel pipe mounting clamp to 8 Nm (71 in lb).
Vacuum hose to plenum.
Air duct to throttle body.
Tighten fuel filler cap.
Negative battery cable.
Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.
Perform the "Idle Learn Procedure." The ECM will need to relearn the IAC valve pintle position following battery re-connect.
FUEL VAPOR PIPES AND HOSES REPAIR/REPLACEMENT

NOTE: When replacing vapor pipes, always replace them with original equipment or parts that meet the GM specifications for those parts. DO NOT use copper or aluminum tubing to replace steel tubing. Only tubing meeting the specification or its equivalent is capable of meeting all pressure and vibration characteristics necessary to ensure the durability standard required.

When replacing vapor hoses or repairing sections of vapor pipe with vapor hoses, always replace them with original equipment or parts meeting GM specifications, use only reinforced fuel-resistant hose which is identified with the word "Fluoroelastomer" or "GM 6163M" on the hose. Inside hose diameter must match outside pipe diameter. DO NOT use rubber hose within 100 mm (4") of any part of the exhaust system or within 254 mm (10") of the catalytic converter. A minimum of 13 mm (1/2") clearance must be maintained around sharp edges such as flanges, pinch welds, etc., to prevent contact and chafing. A minimum of 19 mm (3/4") clearance must be maintained around all moving parts.

REMOVE OR DISCONNECT:

Hardware retaining section of pipe to be replaced. Note location of attaching hardware for installation.
Section of pipe and hoses.
Inspect hoses for cuts, swelling, cracks and distortion. Replace as required.
Inspect pipes for bends, kinks and cracks. Repair or replace sections as required. In the repairable areas, cut a piece of fuel hose 100 mm (4") longer than portion of the line removed. If more than a 152 mm (6") length of pipe is removed, use a combination of steel pipe and hose so that the total hose lengths, including the 100 mm (4") additional length will not be more than 254 mm (10") long.
INSTALL OR CONNECT:

IMPORTANT: Follow the same routing as the original hoses and pipes. Hoses and pipes must be properly secured to prevent charing.

Reverse removal procedure.


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ImpalaSS
Oct 3, 2008.


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