GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Cavalier (CNG) 🢒 Engine 🢒 Engine Controls - 2.2L (L42) 🢒 Fuel Hose/Pipe Replacement - Filter to Union

Tools Required

J 45878 Combustible Gas Detector

Removal Procedure

    Caution: The Compressed Natural Gas (CNG) system operates at pressures up to 24820 kpa (3600 psi). Relieve the CNG fuel system pressure before servicing CNG fuel system components in order to reduce the risk of fire and personal injury.

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

    2. 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.

  2. Disconnect the negative battery cable.

    3. Object Number: 945815 Size: SH
  3. Disconnect the fuel line fitting (2) at the union located beneath the power brake assembly (1).
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information in the J Platform Service Manual.

    5. Object Number: 1084670 Size: SH
  5. Disconnect the fuel line at the fuel filter outlet fitting (2).

    6. Object Number: 102056 Size: SH
  6. Remove the fuel pipe mounting bolts from the body clips.

    7. Object Number: 102255 Size: SH
  7. Remove the fuel pipes from the body clips.
  8. Observe and record the location of the fuel line to body isolators for reference during installation.
  9. Remove the fuel line from the vehicle .

Installation Procedure
  1. Install the fuel line into the vehicle. Ensure that all isolators are in the proper position as recorded during line removal.

    2. Object Number: 102255 Size: SH
  2. Install the fuel line body clips.

    3. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 102056 Size: SH
  3. Install the fuel line body clip mounting bolts.

    4. Tighten
    Tighten the body clip mounting bolts to 6 N·m (53 lb in).


    Object Number: 1084670 Size: SH
  4. Install the fuel line at the fuel filter outlet fitting (2) using a new O-ring face seal. Lubricate the O-ring with petroleum jelly or the equivalent.

    5. Tighten
    Tighten the fuel line fitting to 24 N·m (18 lb ft).

  5. Lower the vehicle.

    6. Object Number: 945815 Size: SH
  6. Connect the fuel line fitting (2) at the union located beneath the power brake assembly (1) using a new O-ring face seal. Lubricate the O-ring with petroleum jelly or the equivalent.

    7. Tighten
    Tighten the fuel line fitting to 24 N·m (18 lb ft).

    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.

  7. Connect the negative battery cable.

    8. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

  8. Start the engine. Inspect for CNG fuel leaks at each serviced fitting using the J 45878 .