GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Aztek - FWD 🢒 Engine 🢒 Engine Cooling 🢒 Secondary Air Injection Crossover Pipe/Hose Replacement

Removal Procedure
  1. Turn OFF the ignition.
  2. Remove the air cleaner intake duct and air cleaner element. Refer to Air Cleaner Inlet Duct Replacement and Air Cleaner Element Replacement .
  3. Remove the ignition control module and coils. Refer to Ignition Control Module Replacement .
  4. Disconnect the upper radiator hose from radiator and reposition. Refer to Radiator Inlet Hose Replacement in Engine Cooling.

    5. Object Number: 541456 Size: SH
  5. Loosen the quick clamps that hold the crossover pipe hose ends to the AIR shut-off valves.
  6. Remove the AIR crossover pipe fastener.
  7. Remove the AIR crossover pipe.

Installation Procedure
  1. Install the AIR crossover pipe.

    2. 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 AIR crossover pipe fastener.

    3. Tighten
    Tighten the bolt to 29 N·m (80 lb in).


    Object Number: 541456 Size: SH
  3. Install the crossover pipe to the shut-off valves.
  4. Connect the upper radiator hose to the radiator. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  5. Install the ignition control module and coils. Refer to Ignition Control Module Replacement .
  6. Install the air cleaner element and air cleaner intake duct. Refer to Air Cleaner Element Replacement and Air Cleaner Inlet Duct Replacement .