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

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the quick-connect fittings at the engine compartment fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service .
  3. Plug the fuel pipes.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Disconnect the quick-connect fittings at the fuel sender fuel feed and return connecting pipes. Refer to Metal Collar Quick Connect Fitting Service .
  6. Remove the exhaust heat shield.

    7. Object Number: 102056 Size: SH
  7. Remove the fuel pipe mounting bolts from the body clips.
  8. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the pipe removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including the hose overlap on the fuel pipe.

    9. Object Number: 102255 Size: SH
  9. Remove the fuel pipes from the body clips.

    10. Object Number: 49888 Size: SH
  10. Remove the fuel pipes (1).

Installation Procedure

    Object Number: 49888 Size: SH
  1. Install the fuel pipes (1).

    2. Object Number: 102255 Size: SH
  2. Position the fuel pipes in the body clips.

    3. Object Number: 102056 Size: SH

    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. Install the fuel pipe mounting bolts into the body clips.

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

  4. Install the exhaust heat shield.

    5. Tighten

        • Tighten the exhaust shield bolt to 2 N·m (18 lb in).
        • Tighten the exhaust shield nuts to 1 N·m (9 lb in).
  5. Remove the caps on the fuel pipes.
  6. Connect the quick-connect fittings at the fuel sender pipes. Refer to Metal Collar Quick Connect Fitting Service .
  7. Lower the vehicle.
  8. Connect the quick-connect fittings at engine compartment fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service .
  9. Connect the negative battery cable.
  10. Inspect for fuel leaks:
    11. 10.1. Turn ON the ignition for two seconds.
    10.2. Turn OFF the ignition for 10 seconds.
    10.3. Turn ON the ignition.
    10.4. Inspect for fuel leaks.