Removal Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
fuel leak. • Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. This will ensure proper reconnection
and prevent a possible fuel leak. (During normal operation, the O-rings located
in the female connector will swell and may prevent proper reconnection if
not lubricated.)
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
Notice: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
Important: Always maintain cleanliness when servicing fuel system components.
- Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
- Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
- Clean the engine fuel pipe connections.
- Clean areas surrounding the engine fuel pipe connections.
- Disconnect the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
- Unclip and remove the fuel lines from the retainers.
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
- Disconnect the fuel return and the EVAP pipe quick-connect fittings in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
- Use a back-up wrench in order to prevent the in-line fuel filter from turning. Remove the threaded fitting nut from the outlet of the fuel filter.
- Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
- Remove the fuel pipes and the EVAP pipe attaching hardware.
- Note the position of the fuel and the EVAP pipes and the attaching hardware for installation.
- Remove the fuel and the EVAP pipes from the vehicle.
- Inspect the pipes for bends, kinks and cracks.
- Repair or replace the pipe or pipes as necessary.
Installation Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.
Notice: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware.
Do not repair sections of fuel pipes.Notice:
• Secure the fuel pipes to the frame in order to prevent chafing.
Maintain a minimum of 13 mm (½ inch) clearance around
a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm
(¾ inch) around any moving part. • Do not allow the fuel pipes to come into contact with the fuel
tank or underbody.
- Install the new fuel feed, the fuel return, and the EVAP pipes to the attaching hardware.
- Install the fuel and the EVAP pipes, as noted during removal.
- Install the fuel and the EVAP pipes retainers to the vehicle.
- Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
- Connect the fuel return and the EVAP pipes quick-connect fittings in front of the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
- Install the fuel feed pipe threaded fitting nut to the outlet of the fuel filter.
- Lower the vehicle.
- Connect the fuel and the EVAP pipes quick-connect fittings in the engine compartment. Refer to Plastic Collar Quick Connect Fitting Service .
- Add fuel and Install the fuel tank filler pipe cap.
- Lower the vehicle.
- Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
- Inspect for leaks.
- Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
Important: If fuel line bundle attaching hardware is damaged or broken, replace the hardware.
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.
Tighten
Tighten the retainers to 10 N·m (89 lb in).
Tighten
Use a back-up wrench in order to prevent the in-line fuel filter from turning. Tighten the fuel filter outlet threaded fitting nut to 30 N·m (22 lb ft).
| 12.1. | Turn ON the ignition for 2 seconds. |
| 12.2. | Turn OFF the ignition for 10 seconds. |
| 12.3. | Turn ON the ignition. |
| 12.4. | Inspect for fuel leaks. |
