Fuel Feed Pipe Replacement - Underbody

Fuel Feed Pipe Replacement - Underbody

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. Relief the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.

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

5. Remove the charge air cooler inlet hose from the turbocharger. 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).




6. Unclip the fuel feed pipe (7) from the retainer clip (2)

7. Disconnect the fuel feed pipe - front (6) at the connector (3) from the fuel feed pipe - underbody (7). Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.

8. Close the fuel feed pipe connectors with CH-6015 - plugs.

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

10. Remove the fuel feed pipe (7) from the upper bulkhead clip (1).

11. Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

12. Remove the catalytic converter. Refer to Catalytic Converter Replacement (2.4L LEA) Catalytic Converter ReplacementCatalytic Converter Replacement (2.0L LHU) Catalytic Converter Replacement.

13. Remove the three-way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.

14. Drain the cooling system. Refer Cooling System Draining and Filling (2.4L LEA) Cooling System Draining and FillingCooling System Draining and Filling (2.0L LHU) Cooling System Draining and Filling.

15. Remove the heater inlet hose. Refer to Heater Inlet Hose Replacement (2.4L LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (2.0L LHU) Heater Inlet Hose Replacement.

16. Remove the heater outlet hose. Refer to Heater Outlet Hose Replacement (2.4L LEA) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (2.0L LHU) Heater Outlet Hose Replacement.

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




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

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




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

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

22. Loosen the drivetrain and front suspension frame bolt (1).




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

24. Remove the underbody front air deflector - right side. Refer to Underbody Front Air Deflector Replacement - Right Side Service and Repair.




25. Open the 4 fuel pipe clips (2).

26. Remove the lower bulk head clip.




27. Disconnect the fuel feed pipe connector (1) from the fuel feed pipe - underbody (4). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

28. Close the fuel feed pipe and fuel tank feed pipe with CH-6015 - plugs.

29. Disconnect the fuel pressure sensor wiring harness plug (2) from the fuel pressure sensor.

30. Open the fuel pipe clip (3) and remove the fuel feed pipe.

31. Remove the fuel pressure sensor from the fuel feed pipe. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.

Installation Procedure

1. Install the fuel pressure sensor to the fuel feed pipe. Refer to Fuel Pressure Sensor Replacement - Fuel Feed Pipe Fuel Pressure Sensor Replacement - Fuel Feed Pipe.

2. Remove the CH-6015 - plugs from fuel feed tank pipe and fuel feed pipe.




3. Install the fuel feed pipe and close the fuel pipe clip (3).

4. Connect the fuel feed pipe - tank (1) to the fuel feed pipe - underbody (4). Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.

5. Install the fuel pressure sensor wiring harness plug (2) to the fuel pressure sensor.




6. Install the lower bulk head clip.

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

8. Install the underbody front air deflector - right side. Refer to Underbody Front Air Deflector Replacement - Right Side Service and Repair.




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

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

11. 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.

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

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

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




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

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

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

18. Install the heater inlet hose. Refer to Heater Inlet Hose Replacement (2.4L LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (2.0L LHU) Heater Inlet Hose Replacement.

19. Install the heater outlet hose. Refer to Heater Outlet Hose Replacement (2.4L LEA) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (2.0L LHU) Heater Outlet Hose Replacement.

20. Install the three-way catalytic converter. Refer to Three-Way Catalytic Converter Replacement (2.4L LEA) Three-Way Catalytic Converter ReplacementThree-Way Catalytic Converter Replacement (2.0L LHU) Three-Way Catalytic Converter Replacement.

21. Install the catalytic converter. Refer to Catalytic Converter Replacement (2.4L LEA) Catalytic Converter ReplacementCatalytic Converter Replacement (2.0L LHU) Catalytic Converter Replacement.

22. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement Turbocharger Heat Shield Replacement.

23. Install the charge air cooler inlet hose to the turbocharger. 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. Lower the vehicle.

25. Close the upper bulk head clip (1).




26. Install the fuel feed pipe (7) to the upper bulkhead clip (1).

27. Close the bulkhead clip (1)

28. Install the fuel feed pipe (7) to the retainer clip (2)

29. Connect the fuel feed pipe - front (6) at the connector (3) to the fuel feed pipe - underbody (7). Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.

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

31. Fill the cooling system. Refer Cooling System Draining and Filling (2.4L LEA) Cooling System Draining and FillingCooling System Draining and Filling (2.0L LHU) Cooling System Draining and Filling.

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

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