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Engine Compartment Fuel Hoses: Installation

WARNING: This page is about a different car, the 2003 Pontiac Grand Am and 2003 Oldsmobile Alero. However, it is still accessible from the selected car via links, so may be relevant.
  1. Connect the fuel flex hoses (1, 5) to the chassis fuel pipes (2, 4). See Figure .
  2. Slide the pin, part of air cleaner assembly, into the bracket hole on the left strut tower.
  3. Position and install the air cleaner inlet over the resonator neck. See Figure .
  4. Install the push in retainer from the air cleaner to the battery tray.
  5. Install the air cleaner assembly bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS  .
  6. Install the relay center and the push in retainer.
  7. Connect the relay battery feed cable into the upper air cleaner cover retaining clips.
  8. Install the battery and battery cables. Tighten to specification. See TORQUE SPECIFICATIONS  .
  9. Connect the air cleaner outlet duct. Tighten the air cleaner outlet duct clamps to specification. See TORQUE SPECIFICATIONS  .


  1. Install and lubricate NEW "O" ring to engine fuel return pipe-to-fuel pressure regulator end, with clean engine oil.
  2. Connect the engine fuel return pipe to the fuel pressure regulator.
  3. Install and lubricate the NEW "O" ring to engine fuel feed pipe-to-fuel rail end, with clean engine oil.
  4. Connect the engine fuel feed pipe to the fuel rail. Tighten the engine fuel pipe fittings to specification. See TORQUE SPECIFICATIONS  .
  5. Install the engine compartment fuel pipe retainer bolt. Tighten the fuel pipe retainer bolt to specification. See TORQUE SPECIFICATIONS  .
  6. Install the upper intake manifold gaskets on the manifold. See Fig 1 .
  7. Apply Thread Lock (GM PN 12345382), or equivalent, to the threads of the bolts. Install the upper intake manifold bolts. See Figure . Tighten the bolts to specification. See TORQUE SPECIFICATIONS  .
  8. Install the MAP sensor and bolts. See Figure .
  9. Connect the MAP sensor vacuum line. Connect the MAP sensor harness connector.
  10. Connect the vacuum modulator.
  11. Install the vacuum hose to the fuel pressure regulator and the crankcase ventilation valve. See Figure .
  12. Connect the TP sensor.
  13. Connect the IAC valve.
  14. Connect the injector harness.
  15. Connect the coolant hoses from the throttle body.
  16. Install the EVAP canister purge solenoid. See Figure .
  17. Install the electronic ignition coil and module assembly. See Figure .
  18. Install the EGR pipe, if equipped.
  19. Install the throttle cables and bracket to the throttle body.
  20. Install the brake vacuum pipe.
  21. Fill and bleed the cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM.
  22. Connect the quick-connect fittings in the engine compartment.
  23. Connect the negative battery cable.
  24. Inspect for fuel leaks using the following procedures:
    • Turn ignition switch to RUN position, with the engine OFF for 2 seconds.
    • Turn ignition switch to OFF position for 10 seconds.
    • Turn ignition switch to OFF position, with the engine OFF.
    • Check for fuel leaks.
Fig 1: Installing Upper Intake Manifold Gaskets
G00226899Courtesy of GENERAL MOTORS CORP.
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