Fuel Supply Line: Service and Repair

Fuel Lines

3.5L Vehicles










3.5L Gasoline Turbocharged Direct Injection (GTDI) Vehicles









Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. With vehicle in NEUTRAL, position it on a hoist.

2. Release the fuel system pressure.

3. Disconnect the battery ground cable.

4. NOTE: Some residual fuel may remain in the fuel tubes after releasing the fuel system pressure. When disconnecting or removing any fuel tubes, carefully drain any residual fuel into a suitable container.
Disconnect the fuel tube-to-fuel rail jumper tube quick connect coupling.

3.5L vehicles

5. Disconnect the vapor tube-to-Evaporative Emission (EVAP) canister purge valve quick connect coupling.

6. Remove the stud and release the fuel tubes from the bundle retainer.
- To install, tighten to 20 Nm (177 lb-in).


3.5L Gasoline Turbocharged Direct Injection (GTDI) vehicles

7. Disconnect the EVAP (Evaporative Emission) canister purge valve-to-vapor tube quick connect coupling.

8. Remove the 2 bolts and release the fuel tubes from the bundle retainers.
- To install, tighten to 9 Nm (80 lb-in).


All vehicles

9. Disconnect the vapor tube-to-EVAP (Evaporative Emission) canister quick connect coupling.

10. Disconnect the fuel tube-to-fuel jumper tube quick connect coupling.

11. Remove the 2 nuts and position the fuel tube bundle shield and the EVAP (Evaporative Emission) canister shield aside.
- To install, tighten to 9 Nm (80 lb-in).


12. Release the fuel tubes from the fuel tube bundle shield and remove the tubes.

13. To install, reverse the removal procedure.