GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the engine cover. Refer to Engine Cover Replacement.

  3. Object Number: 2028059  Size: SH
  4. Remove the fuel return front hose clamp (3).
  5. Remove the fuel return front hose (2) from the fuel return pipe to fuel injection pump.

  6. Object Number: 2028092  Size: SH
  7. Unclip the fuel return pipe (1) from the bracket clip (2) and (4).
  8. Open the bracket clip (3) and remove the fuel return pipe.
  9. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement.

  10. Object Number: 2028091  Size: SH
  11. Remove the 4 exhaust pipe front hanger bolts (2).
  12. Remove the drivetrain and front suspension frame bolt (3)
  13. Remove the drivetrain and front suspension frame.

  14. Object Number: 2028093  Size: SH
  15. Unclip the fuel return pipe (1) from the 4 bracket clips (2).

  16. Object Number: 2028094  Size: SH
  17. Unclip the fuel return pipe (3) from the rear bracket clip (2).
  18. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1).
  19. Remove the fuel return pipe (3).

Installation Procedure


    Object Number: 2028094  Size: SH
  1. Install the fuel return pipe (3).
  2. Connect the fuel return pipe (3) to the fuel return pipe connector (1).
  3. Clip in the fuel return pipe (3) to the rear bracket clip (2).

  4. Object Number: 2028093  Size: SH
  5. Clip in the fuel return pipe (1) to the 4 bracket clips (2).

  6. Object Number: 2028091  Size: SH
  7. Install the drivetrain and front suspension frame.
  8. Caution: Refer to Fastener Caution in the Preface section.

  9. Install the drivetrain and front suspension frame bolt (3) and tighten to  XX N·m (XX lb ft).
  10. Install the 4 exhaust pipe front hanger bolts (2) and tighten to  20 N·m (15 lb ft).
  11. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement.

  12. Object Number: 2028092  Size: SH
  13. Clip in the fuel return pipe (1) to the bracket clip (2) and (4).
  14. Install the fuel return pipe to the bracket clip (3) and look the bracket clip.

  15. Object Number: 2028059  Size: SH
  16. Install the fuel return front hose (2) from the fuel return pipe to fuel injection pump.
  17. Install the fuel return front hose clamp (3).
  18. Install the engine cover. Refer to Engine Cover Replacement.
  19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.