Fuel Hose/Pipes Replacement - Chassis

FUEL HOSE/PIPES REPLACEMENT - CHASSIS

REMOVAL PROCEDURE

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




1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Disconnect the fuel feed pipe (1) at the fuel rail.
3. Disconnect the evaporative emission (EVAP) canister purge pipe (2).
4. Cap the fuel rail and EVAP pipes.
5. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
6. Unbolt and reposition the front propeller shaft.




7. Remove the fuel pipe bracket nut.
8. Remove the fuel pipe bracket from the bellhousing stud.




9. Remove the fuel line 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 bolt.




13. Disconnect the fuel feed and EVAP pipes from the fuel tank lines.
14. Cap the fuel and EVAP pipes at the fuel tank.




15. Remove the fuel and EVAP line clips from the frame and brace.
16. Remove the fuel/EVAP line bundle.

INSTALLATION PROCEDURE




1. Install the fuel/EVAP line bundle.
2. Install the fuel and EVAP line clips to the frame and brace.




3. Remove the caps from the fuel pipes at the fuel tank.
4. Connect the fuel feed and EVAP pipes to the fuel tank pipes.




5. Insert the integral locator tab into the hole in the frame.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the fuel pipe/hose bracket bolt.

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

7. Install the EVAP canister.




8. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
9. Install the fuel hose/pipe clip to the bracket on the automatic transmission.




10. Install the fuel pipe bracket to the bellhousing stud.
11. Install the fuel pipe bracket nut (2).

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

12. Reposition and install the front propeller shaft bolts.




13. Lower the vehicle.
14. Remove the caps from the fuel rail and EVAP pipes.
15. Connect the EVAP canister purge line (2).
16. Connect the fuel feed line (1) at the fuel rail.
17. Install the fuel fill cap.
18. Connect the negative battery cable.
19. Use the following procedure in order to inspect for leaks:
1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.