GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Bonneville 🢒 Engine 🢒 Engine Controls - 3.8L 🢒 Secondary Air Injection Pump Outlet Pipe/Hose Replacement

Removal Procedure

    Object Number: 867127 Size: SH
  1. Remove the outlet hose clamps (1) from the intermediate pipe and Air Injection Reaction (AIR) pump.
  2. Disconnect the outlet hose (2) from the intermediate pipe and AIR pump.
  3. Remove the outlet hose (2) from the vehicle.

    4. Object Number: 203920 Size: SH
  4. Remove the throttle body support bracket fasteners.
  5. Remove the throttle body support bracket from the vehicle.

    6. Object Number: 507664 Size: SH
  6. Remove the AIR outlet pipe (2) retaining nut.
  7. Remove the AIR outlet pipe hose clamp from the AIR shut-off valve.
  8. Disconnect the AIR outlet pipe hose (1) from the AIR shut-off valve.
  9. Remove the outlet pipe (2) from the vehicle.

Installation Procedure

    Object Number: 507664 Size: SH
  1. Install the Air Injection Reaction (AIR) outlet pipe (2) to the vehicle.
  2. Connect the AIR outlet pipe hose (1) to the AIR shut-off valve.
  3. Install the AIR outlet pipe hose clamp to the AIR shut-off valve.
  4. Install the AIR outlet pipe (2) retaining nut.

    5. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 203920 Size: SH
  5. Install the throttle body support bracket to the vehicle.
  6. Install the throttle body support bracket fasteners.

    7. Tighten
    Tighten the fasteners to 10 N·m (89 lb in).


    Object Number: 867127 Size: SH
  7. Install the AIR outlet hose (2) to the vehicle.
  8. Connect the outlet hose (2) to the intermediate pipe and AIR pump.
  9. Install the outlet hose clamps (1) to the intermediate pipe and AIR pump.