Fuel Hose/Pipes Replacement

Fuel Hose/Pipes Replacement - Chassis


IMPORTANT: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination.







REMOVAL PROCEDURE
1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
Fuel Pressure Release
2. Disconnect the fuel feed and return pipes (1) at the fuel rail.
3. Disconnect the evaporative emission (EVAP) canister purge tube (3).
4. Cap the fuel rail and EVAP pipes.
5. Raise and suitably support the vehicle. Refer to Vehcile Lifting.
6. Unbolt and reposition the front propeller shaft. Refer to Propeller Shaft Replacement - Front.
7. Remove the fuel pipe bracket nut (2).
8. Remove the fuel pipe bracket from the bellhousing stud.







9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission.







10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.







11. Remove the EVAP canister.
12. Remove the fuel filter bracket bolts (2).
13. Remove the fuel pipe/hose bracket (1) bolt.







14. Disconnect the fuel feed and return pipes (4) from the fuel tank pipes (3).
15. Cap the fuel pipes at the fuel tank.







16. Remove the fuel hose/pipe clips from the frame and brace.
17. Remove the EVAP hose/pipe clips from the brace.
18. Remove the fuel pipe/hose assembly.







INSTALLATION PROCEDURE
1. Install the fuel pipe/hose assembly.
2. Install the EVAP hose/pipe clips to the brace.
3. Install the fuel hose/pipe clips to the frame and brace.
4. Remove the caps from the fuel pipes at the fuel tank.







5. Connect the fuel feed and return pipes (4) to the fuel tank pipes (3).







6. Insert the integral locator tab (3) into the hole in the frame.

NOTE: Refer to Fastener Notice in Service Precautions Fastener Notice.

7. Install the fuel pipe/hose bracket (1) bolt.

Tighten
Tighten the bolt to ................................12 N.m (106 lb in).

8. Install the fuel filter bracket bolts (2).

Tighten
Tighten the bolts to ...................................12 N.m (106 lb in).

9. Install the EVAP canister.







10. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.







11. Install the fuel hose/pipe clip to the bracket on the automatic transmission.







12. Install the fuel pipe bracket to the bellhousing stud.

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

13. Install the fuel pipe bracket nut (2).
14. Reposition and install the front propeller shaft bolts.
15. Lower the vehicle.
16. Remove the caps from the fuel rail and EVAP pipes.
17. Connect the EVAP canister purge tube (3).
18. Connect the fuel feed and return pipes (1) at the fuel rail.
19. Install the fuel fill cap.
20. Connect the negative battery cable.
21. Use the following procedure in order to inspect for leaks:
21.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
21.2. Turn the ignition OFF for 10 seconds.
21.3. Turn the ignition ON, with the engine OFF.
21.4. Inspect for fuel leaks.