Fuel Hose/Pipes Replacement - Chassis
REMOVAL PROCEDUREIMPORTANT: Clean the fuel/EVAP pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel/EVAP system.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the fuel feed and return pipes (1) at the fuel rail.
3. Disconnect the evaporative emission (EVAP) canister purge pipe (3).
4. Cap the fuel rail and EVAP pipes in order to prevent possible contamination of the EVAP/fuel system.
5. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
6. If equipped with 4 wheel drive (4WD), remove the front propeller shaft.
7. Remove the exhaust muffler nuts.
8. Disconnect the catalytic converter from the exhaust muffler.
9. Remove the bolts attaching the transmission crossmember to the frame.
10. Lower the transmission slightly, only until the catalytic converter almost contacts the crossmember mounting frame bracket.
IMPORTANT: Do not allow the catalytic converter to support any weight by resting against the frame as damage to the catalytic converter or exhaust manifolds may result.
11. Remove the EVAP/fuel hose/pipe bracket nut (2).
12. Remove the fuel hose/pipe bracket from the bellhousing stud.
13. If equipped with 2 wheel drive (2WD), remove the EVAP/fuel hose/pipe assembly from the retaining clips (1) on the transmission.
14. If equipped with 4WD, remove the EVAP/fuel hose/pipe assembly from the retaining clips (1) on the transmission.
15. Disconnect the fuel return pipe and evaporative emission (EVAP) pipe from the fuel tank pipes.
16. Disconnect the fuel feed pipe from the fuel filter.
17. Cap the fuel filter and pipes at the fuel tank.
18. Remove the EVAP/fuel hose/pipe assembly from the vehicle.
19. Remove the EVAP/fuel hose/pipe assembly retaining clips.
IMPORTANT: Note the position of the EVAP/fuel hose/pipe assembly clips prior to disassembly.
20. Remove the fuel feed or return pipe to be replaced from the EVAP/fuel hose/pipe assembly.
INSTALLATION PROCEDURE
1. Install the fuel feed or return pipe to the EVAP/fuel hose/pipe assembly.
2. Install the EVAP/fuel hose/pipe assembly retaining clips.
3. Install the EVAP/fuel hose/pipe assembly to the vehicle.
4. Remove the caps from the fuel filter and pipes at the fuel tank.
5. Connect the fuel return pipe and EVAP pipe to the fuel tank pipes.
6. Connect the fuel feed pipe to the fuel filter.
7. Install the EVAP/fuel hose/pipe assembly to the clips on the automatic transmission.
8. Install the EVAP/fuel hose/pipe bracket to the bellhousing stud.
NOTE: Refer to Fastener Notice in Service Precautions.
9. Install the EVAP/fuel hose/pipe bracket nut (2).
Tighten
Tighten the nut to 10 N.m (89 lb in).
10. Lower the vehicle.
11. Remove the caps from the fuel rail and EVAP pipes.
12. Connect the EVAP canister purge pipe (3).
13. Connect the fuel feed and return pipes (1) at the fuel rail.
14. Install the fuel fill cap.
15. Connect the negative battery cable.
16. Use the following procedure to inspect for leaks:
16.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
16.2. Turn the ignition OFF for 10 seconds.
16.3. Turn the ignition ON, with the engine OFF.
16.4. Inspect for leaks.