GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Cavalier 🢒 Engine 🢒 Engine Electrical 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Object Number: 161923 Size: SH
  2. Remove the air cleaner outlet resonator (1). Refer to Air Cleaner Outlet Resonator Replacement .

    3. Object Number: 143272 Size: SH
  3. Remove the air cleaner resonator bracket (1).
  4. Disconnect the fuel supply hose from the fuel rail assembly. Refer to Metal Collar Quick Connect Fitting Service .
  5. Using a back-up wrench disconnect the fuel return hose from the fuel pressure regulator.
  6. Discard the fuel pressure regulator O-ring.
  7. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  8. Disconnect the fuel return hose from the chassis fuel return pipe. Refer to Metal Collar Quick Connect Fitting Service .
  9. Disconnect the fuel supply hose from the chassis fuel supply pipe. Refer to Metal Collar Quick Connect Fitting Service .
  10. Plug the fuel pipes, fuel hoses, fuel pressure regulator and fuel rail to prevent contamination of the fuel system.

Installation Procedure
  1. Remove the plugs from the fuel pipes, fuel hoses, fuel pressure regulator and fuel rail.
  2. Connect the fuel supply hose to the chassis fuel supply pipe. Refer to Metal Collar Quick Connect Fitting Service .
  3. Connect the fuel return hose to the chassis fuel return pipe. Refer to Metal Collar Quick Connect Fitting Service .
  4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  5. Install a new fuel pressure regulator O-ring to the fuel return hose.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Using a back-up wrench, connect the fuel return hose to the fuel pressure regulator .

    7. Tighten
    Tighten the fuel return fitting to 33 N·m (24 lb ft).

  7. Connect the fuel supply hose to the fuel rail assembly. Refer to Metal Collar Quick Connect Fitting Service .
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  9. Inspect for fuel leaks using the following procedure:
    10. 9.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    9.2. Turn OFF the ignition for 10 seconds.
    9.3. Turn ON the ignition, with the engine OFF.
    9.4. Inspect for fuel leaks.

    Object Number: 143272 Size: SH
  10. Install the air cleaner resonator bracket (1).

    11. Tighten

    1. Tighten the bracket nuts (4) to 10 N·m (89 lb in).
    2. Tighten the bracket nut (3) to 25 N·m (18 lb ft).
    3. Tighten the bracket bolt (2) to 25 N·m (18 lb ft).

    Object Number: 161923 Size: SH
  11. Install the air cleaner outlet resonator (1). Refer to Air Cleaner Outlet Resonator Replacement .