GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Cavalier 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Hose/Pipes Replacement - Engine Compartment

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  4. Disconnect the quick-connect fittings at the engine compartment fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service .
  5. Plug the fuel pipes.
  6. Remove the fuel feed and return pipe retainers and screws.
  7. Disconnect the fuel return pipe from the fuel pressure regulator.
  8. Disconnect the fuel feed pipe from the fuel rail.
  9. Discard the O-rings.

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

    3. 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.

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

    4. Tighten
    Tighten the fuel return pipe bracket screw to 9.5 N·m (84 lb in).

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

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

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

    8. Tighten
    Tighten the screws to 12 N·m (106 lb in).

  8. Connect the negative battery cable.
  9. Inspect for fuel leaks:
    10. 9.1. Turn ON the ignition for 2 seconds.
    9.2. Turn OFF the ignition for 10 seconds.
    9.3. Turn ON the ignition.
    9.4. Inspect for fuel leaks.
  10. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  11. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .