Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (Fuel Pressure Relief (With CH-48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
3. Remove air cleaner assembly. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
4. Disconnect the brake pressure modulator valve from the body to provide clearance for the fuel pipes. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair)
5. Disconnect the fuel feed pipe (2) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
6. Disconnect the evaporative emission (EVAP) pipe (3) quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Cap the fuel rail and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.




8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
9. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
10. Disconnect the fuel pump fuel feed pipe quick connect fitting (6) from the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
11. Disconnect the EVAP canister vent front pipe quick connect fitting (5) from the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
12. Remove the fuel feed/EVAP pipe assembly clip (1) from the body.
13. Remove the fuel feed/EVAP pipe assembly clip nut (3) and clip (2) from the stud.
14. Loosen the fuel feed/EVAP pipe clip (4) bolt, and remove the fuel feed/EVAP pipe assembly from the vehicle.
15. Mark the location of the retainers on the new pipes and remove the plastic retainers from the old pipes using a soapy solution.

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution)

1. Position the fuel feed and EVAP pipes to the vehicle individually, and install the plastic retainers to the marked locations. Tighten the fuel feed/EVAP pipe clip (4) bolt to 8 Nm (71 lb in).
2. Install the fuel feed/EVAP pipe clip (2) and nut (3) to the stud and tighten to 9 Nm (80 lb in).
3. Install the fuel feed/EVAP pipe clip (1) to the body.
4. Connect the EVAP canister vent front pipe quick connect fitting (5) to the chassis EVAP pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Connect the fuel pump fuel feed pipe quick connect fitting (6) to the chassis fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
6. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).




7. Remove the caps from the fuel rail and the EVAP purge solenoid.
8. Connect the EVAP pipe (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Connect the fuel feed pipe (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
10. Tighten the fuel fill cap.
11. Use the following procedure in order to inspect for leaks:

* Turn the ignition ON, with the engine OFF, for 2 seconds.
* Turn the ignition OFF for 10 seconds.
* Turn the ignition ON, with the engine OFF.
* Inspect for fuel leaks.

12. Reconnect the brake pressure modulator valve from the body to provide clearance for the fuel pipes. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair)
13. Install the air cleaner assembly. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
14. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).