GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Cavalier 🢒 Body and Accessories 🢒 Body Front End 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the quick-connect fittings at engine compartment fuel feed and return connecting lines. Refer to Metal Collar Quick Connect Fitting Service .
  3. Plug the fuel lines.
  4. Remove the engine fuel feed and return pipe retainer and screws.
  5. Remove the fuel return pipe from the fuel pressure regulator using a back-up wrench.
  6. Remove the fuel pipe from fuel rail.
  7. Discard O-rings.

Installation Procedure
  1. Remove the plugs on the fuel pipes.
  2. Install the new O-rings.

    3. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  3. Install the fuel return pipe to the fuel pressure regulator.

    4. Tighten
    Tighten the retainer screw to the regulator to 6 N·m (53 lbs in).

  4. Install the fuel feed pipe to the fuel rail using a back-up wrench.

    5. Tighten
    Tighten the fuel fitting to 30 N·m (22 lbs ft).

  5. Install the quick-connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
  6. Install the fuel line retainer.
  7. Install the fuel line clamp screws.

    8. Tighten
    Fuel line clamp screws to 12 N·m ( 106 lbs in).

  8. Install the negative battery cable.
  9. Inspect for fuel leaks through the following steps:
    10. 9.1. Turn the ignition switch to the ON position for two seconds.
    9.2. Turn the ignition switch to the OFF position for ten seconds.
    9.3. Turn the ignition switch to the ON position.
    9.4. Check for fuel leaks.