GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Steering 🢒 Power Steering System 🢒 Power Steering Return Hose Replacement

Removal Procedure

    Object Number: 648319 Size: SH
  1. Remove the drive belt from the power steering pump pulley. Refer to Drive Belt Replacement in Engine Mechanical - 3.1L.
  2. Remove the power steering hose retainer nut (1) and the retainer (2).

    3. Object Number: 441201 Size: SH
  3. Remove the power steering return hose (3) from the power steering pump (1).
  4. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the power steering return hose (3) from the retainer (6).
  6. Remove the power steering return hose (3) from the power steering gear (5).
  7. Remove the power steering return hose (3) from the vehicle.

Installation Procedure
  1. Install the power steering return hose (3) to the vehicle.

    2. Object Number: 441201 Size: SH

    Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage.

    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.

  2. Install the power steering return hose (3) to the power steering gear (5).

    3. Tighten
    Tighten the fitting to 27 N·m (20 lb ft).

  3. Install the power steering return hose (3) to the retainer (6).
  4. Lower the vehicle.
  5. Install the power steering return hose (3) to the power steering pump (1).

    6. Tighten
    Tighten the fitting to 27 N·m (20 lb ft).


    Object Number: 648319 Size: SH
  6. Install the power steering hose retainer (2) and the retainer nut (1).

    7. Tighten
    Tighten the nut to 5 N·m (45 lb in).

  7. Ensure that the power steering hose has sufficient clearance from the exhaust manifold.
  8. Install the drive belt to the power steering pump pulley. Refer to Drive Belt Replacement in Engine Mechanical - 3.1L.
  9. Bleed the air from the power steering system. Refer to Power Steering System Bleeding .