Evaporative Emissions Hose: Service and Repair

Evaporative Emission Front Pipe Replacement

Special Tools

* CH-807 - Closure Plugs

* CH-6015 - Closure Plugs

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

3. Remove the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement Service and Repair.

4. Remove the charge air cooler inlet hose - turbocharger side. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).




5. Disconnect the EVAP pipe (5) from the EVAP pipe - chassis (7) at the connector (3). Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.

6. Remove the EVAP pipe (5) from the EVAP solenoid at the connector (6). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

7. Unclip the EVAP pipe (5) from the retainer clip (4).

8. Remove the EVAP pipe (5).

9. Unclip the EVAP pipe (7) from the retainer clip (2).

10. Open the upper bulk head clip (1).

11. Remove the EVAP pipe (7) from the upper bulkhead clip (1).

12. Close the EVAP pipe connectors with CH-6015 - plugs.

13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

14. Remove the steering gear heat shield. Refer to Steering Gear Heat Shield Replacement Steering Gear Heat Shield Replacement.




15. Remove the brake and fuel pipe heat shield retainers (2).

16. Remove the brake and fuel pipe heat shield (1).




17. Remove and DISCARD the exhaust front hanger bracket bolt (3).

18. Remove and DISCARD the frame reinforcement bolt (2).

19. Loosen the drive train and front suspension frame bolt (1).




20. Rotate the right frame reinforcement (1) to a position shown to get access to the fuel pipes.




21. Open the 4 EVAP pipe clips (2).

22. Remove the lower bulk head clip.




23. Disconnect the fuel EVAP pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

24. Close the EVAP pipe and EVAP canister pipe with CH-6015 - plugs.

25. Remove the EVAP pipe clip (2).

Installation Procedure

1. Remove the CH-6015 - plugs from EVAP canister pipe and EVAP pipe.




2. Install the EVAP pipe clip (2).

3. Connect the fuel EVAP pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.




4. Install the lower bulk head clip.

5. Close the 4 fuel pipe clips (2).




6. Rotate the right frame reinforcement to its original position.

7. Install the exhaust front hanger bracket bolt (3).

8. Install the frame reinforcement bolt (2).

Caution: Refer to Fastener Caution Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

9. Tighten the NEW exhaust front hanger bracket bolt (3) to 22 Nm (16 lb ft).

10. Tighten the NEW frame reinforcement bolt (2) to 60 Nm (44 lb ft).

11. Tighten the drivetrain and front suspension frame bolt (1) to 160 Nm (118 lb ft).




12. Install the brake and fuel pipe heat shield (1).

13. Install the brake and fuel pipe heat shield retainers (2).

14. Install the steering gear heat shield. Refer to Steering Gear Heat Shield Replacement Steering Gear Heat Shield Replacement.

15. Lower the vehicle.




16. Install the EVAP pipe (7) to the upper bulkhead clip (1).

17. Install the upper bulk head clip (1).

18. Clip the EVAP pipe (7) into the retainer clip (2).

19. Install the EVAP pipe (5).

20. Connect the EVAP pipes at the connector (3). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

21. Clip the EVAP pipe (5) to the retainer clip (4)

22. Connect the EVAP pipe to the EVAP solenoid at the connector (6). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

23. Install the charge air cooler inlet hose - turbocharger side. Refer to Charge Air Cooler Inlet Hose Replacement (Turbocharger) Charge Air Cooler Inlet Hose Replacement (Turbocharger)Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler) Charge Air Cooler Inlet Hose Replacement (Charge Air Cooler).

24. Install the dash upper extension panel. Refer to Dash Upper Extension Panel Opening Cover Replacement Service and Repair.

25. Install the engine sight shield. Refer to Engine Sight Shield Replacement Engine Sight Shield Replacement.

26. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.