Fuel Lines

Fuel Lines

Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Release the fuel system pressure.

3. Disconnect the fuel supply tube-to-fuel rail quick connect coupling.

4. Disconnect the Evaporative Emission (EVAP) canister vapor tube-to-EVAP (Evaporative Emission) purge valve quick connect coupling.

5. NOTE: LH side shown, RH side similar.

If equipped, remove the 6 bolts and the transfer case skid plate.






6. If equipped, remove the front driveshaft.

7. Disconnect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling.

8. Disconnect the EVAP (Evaporative Emission) canister vapor tube-to-EVAP (Evaporative Emission) canister quick connect coupling and fresh air tube-to-EVAP (Evaporative Emission) canister quick connect coupling.

9. If equipped, remove the selector lever heat shield.





10. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.





11. Remove the 2 selector lever bracket bolts and remove the bracket.





12. Remove the front fuel supply tube, fuel vapor tube and fresh air tube pushpin from the bracket at the transmission bellhousing.

13. Disconnect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and remove the HO2S (Heated Oxygen Sensor) electrical connector wiring pushpin from the fuel supply tube, fuel vapor tube and fresh air tube bracket at the rear of the transmission housing.





14. NOTE: Front pushpin retainer shown, others similar.

Disconnect the 3 transmission wiring harness pushpin retainers from the bracket at the transmission bellhousing, the transmission housing and the bracket at the rear of the transmission.






15. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the bracket at the rear of the transmission housing.

16. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the vehicle.

Installation

1. Install the fresh air tube into the vehicle and connect the pushpin retainer to the bracket at the bellhousing and install the line into the bracket at the rear of the transmission.

2. Install the front fuel supply tube into the vehicle and clip it into the bracket at the bellhousing and install it into the bracket at the rear of the transmission.

3. Install the fuel vapor tube into the vehicle and clip it into the bracket at the bellhousing and install it into the bracket at the rear of the transmission.

4. NOTE: Front pushpin retainer shown, others similar.

Connect the 3 transmission wiring harness pushpin retainers to the bracket at the transmission bellhousing, the transmission housing and the bracket at the rear of the transmission.






5. Install the HO2S (Heated Oxygen Sensor) electrical connector wiring pushpin to the fuel supply tube, fuel vapor tube, and fresh air tube bracket at the rear of the transmission housing and connect the LH HO2S (Heated Oxygen Sensor) sensor electrical connector.





6. Install the selector lever bracket and 2 bolts.
- Tighten to 48 Nm (35 lb-ft).






7. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked in the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed.

With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud and move the locking tab downward into the locked position.

- Listen for the audible click.

- Pull back on the selector lever cable to make sure it is correctly installed.






8. If equipped, install the selector lever heat shield.





9. Connect the EVAP (Evaporative Emission) canister vapor tube-to-EVAP (Evaporative Emission) canister quick connect coupling and fresh air tube-to-EVAP (Evaporative Emission) canister quick connect coupling.

10. Connect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling.

11. If equipped, install the front driveshaft.

12. NOTE: LH side shown, RH side similar.

If equipped, install the transfer case skid plate and 6 bolts.

- Tighten to 25 Nm (18 lb-ft).






13. Connect the fuel supply tube-to-fuel rail quick connect coupling.

14. Connect the EVAP (Evaporative Emission) canister fuel vapor tube-to-EVAP (Evaporative Emission) purge valve quick connect coupling.