Fuel Hose/Pipes Replacement - Chassis

FUEL HOSE/PIPES REPLACEMENT - CHASSIS

REMOVAL PROCEDURE




1. Position on the hoist.

CAUTION: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

NOTE: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.




2. Disconnect the negative battery terminal.

CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.




3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.

CAUTION: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

4. Raise the vehicle to a comfortable working height.
5. Remove the stone chip guard.




6. Disengage the chassis fuel feed, return, and EVAP canister purge lines from the front fuel feed, return, and EVAP canister purge lines located near passenger's front wheel well.

IMPORTANT: To facilitate the removal, it may be necessary to spray quick connects with penetrating oil to remove debris.




7. Disengage the fuel feed, after the fuel filter, return, and EVAP canister purge line at the fuel tank.
8. Release the fuel line bundle from the underbody plastic retainers.
9. Remove the damaged fuel line.

INSTALLATION PROCEDURE




1. Make sure lines are not kinked, bent, or damaged.

NOTE:
- Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
- Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

2. Install the fuel and vapor hoses. Make sure the lines are properly routed.
3. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.




4. Install the stone chip guard.

NOTE: Refer to Fastener Notice in Service Precautions.

Tighten the fuel line stone chip guard to 12 N.m (106 lb in).

5. Install the underbody retaining clips. Hammer in place using a rubber mallet.




6. Lower the vehicle.
7. Connect the negative battery terminal.

Tighten the battery terminal bolts to 17 N.m (13 lb ft).

8. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
2. Repeat step 8.1 twice.
3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
4. If the engine does not start, repeat steps 8.1-8.4.
9. Run the engine and check the system for leaks.