Fuel Hoses and Pipes/Chassis

Removal Procedure

Notice: If it is necessary to remove rust or burrs from a fuel pipe, use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.

2. Remove the quick-connect fittings at the engine compartment fuel feed and return connecting lines. Refer to Quick Connect Fitting(s) Service (Metal Collar).

3. Disconnect and plug the fuel lines.

4. Raise the vehicle.

5. Remove the quick-connect fittings at the fuel sender and the nylon fuel feed and return connecting lines. Refer to Quick Connect Fitting(s) Service (Metal Collar).

6. Disconnect and plug the fuel lines in order to prevent leakage.

7. Remove the fuel pipe mounting hardware from the pipes.

8. Remove the fuel pipes to be serviced.

9. In the repairable areas, cut a piece of fuel hose 100 mm (4 in) longer than portion of the line removed. If more than a 152 mm (6 in) length of pipe is removed, use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 in), including hose overlap on fuel line.

Installation Procedure

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Position the fuel pipe or the line in the body clips.

2. Install the fuel pipe and the hose hardware.

3. Remove the caps on the lines.

4. Install the quick-connect fittings on the fuel lines. Refer to Quick Connect Fitting(s) Service (Metal Collar).

5. Lower the vehicle.

6. Remove the caps covering the fuel lines, if required.

7. Install the engine compartment fuel line quick-connect fittings. Refer to Quick Connect Fitting (5) Service (Metal Collar).

8. Install the fuel filler cap.

9. Connect the negative battery cable.

10. Inspect for fuel leaks through the following steps:

10.1. Turn the ignition switch to the ON position for two seconds.

10.2. Turn the ignition switch to the OFF position for ten seconds.

10.3. Turn the ignition switch to the ON position.

10.4. Check for fuel leaks.