Fuel Hose/Pipes Assembly Replacement

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draming Procedure (Utility with Dual Tanks - Rear Tank).
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Clean all the fuel pipe and hose connections and the surrounding areas before disconnecting in order to avoid possible contamination of the fuel system.
6. Remove the fuel tank.




7. Remove the rear fuel feed pipe (4) and the rear fuel return pipe (5) from the fuel sender (2) and the fuel tank clips (6).
8. Cap the fuel pipes in order to prevent possible fuel system contamination.

INSTALLATION PROCEDURE




1. Remove the caps from the fuel pipes.
2. Connect the rear fuel feed pipe (4) and the rear fuel return pipe (5) to the fuel sender (2) and the fuel tank clips (6).




3. Install the fuel tank.
4. Lower the vehicle.
5. Refill the fuel tank.
6. Connect the negative battery cable.
7. Tighten the fuel filler cap.
8. Inspect for leaks.
8.1. Turn the ignition ON for 2 seconds.
8.2. Turn the ignition OFF for 10 seconds.
8.3. Turn the ignition ON.
8.4. Inspect for fuel leaks.