Service Procedure

1. Raise and support the hood. Examine the Front Fuel Feed Hose Assembly. If the hose assembly is P/N 24570910 part, as shown in Figure 1, proceed directly to Step 9. Otherwise, proceed to Step 2.



2. Note owner's radio station choices, then disconnect negative battery cable and remove fuel tank filler cap.

3. Relieve pressure in fuel system following instructions below:

CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before servicing fuel system components, otherwise fuel spray could occur. Have a dry chemical (Class B) fire extinguisher near the work area.

A. Connect fuel gauge J 34430-1 or equivalent to fuel pressure connection. Wrap a shop cloth around fitting while connecting gauge to collect fuel. Then place cloth in an approved container.

B. Install bleed hose into the approved container and open valve to bleed system pressure. Drain an fuel remaining in the gauge into an approved container.

4. Disconnect Front Fuel Feed Hose at engine and body fuel feed pipes utilizing a back-up wrench on fittings. Take care not to lose the seal and washer at the fuel rail. Remove bolt and pipe clamp on engine.



5. Examine the O-ring seal and the white plastic (washer) retainer in the end of the fuel rail; determine that they are undamaged and in proper position for reuse. Examine the O-ring on the body fuel feed pipe, making sure O-ring is in proper position and undamaged for reuse. See Figure 2.

IMPORTANT:
When the Front Fuel Feed hose/pipe fitting is disconnected at the Fuel Rail, there are two ways in which the retainer (white plastic washer) may be moved out of position: If the pipe is cocked while being withdrawn from the fuel rail, the retainer may be cocked or pulled slightly out. Also, the weight of the fuel in the fuel rail may push the retainer out of position when the fuel feed hose/pipe is withdrawn. If the new Front Fuel Feed Hose is installed without first ensuring the retainer is correctly positioned (square and fully seated), the connection may leak.

6. Obtain new Front Fuel Feed Hose (Service P/N 24570910). Install the new Front Fuel Feed Hose to the engine fuel rail and to the body fuel feed pipe fitting, ensuring hose is not kinked or twisted. Torque the pipe nut at the fuel rail to 30 N-m (22 lbs.ft.) and the hose fitting at the body pipe to 27 N-m (20 lbs.ft.), utilizing a backup wrench on fittings.

Reinstall bolt and pipe clamp, torquing bolt to 12 N-m (106 lbs.in.).

Ensure that there is at least 13 mm (1/2 inch) clearance between the fuel feed hose and any sharp edges. Do likewise for the fuel return hose assembly.

7. Reinstall fuel tank filler cap and reconnect the negative battery cable. Reset clock and radio station preset buttons to owner's choices noted at Step 2.

8. Start engine and check for possible fuel leaks and correct as required. Also check the fuel pressure connection for leaks.

9. Install a Campaign Identification Label.