Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

1. Disconnect the negative battery cable.






Important: Clean the fuel/evaporative emission (EVAP) pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible contamination of the fuel/EVAP system.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
3. Disconnect the fuel feed pipe (3) at the fuel rail (2).
4. Disconnect the EVAP canister purge pipe (1, 4).
5. Cap the fuel rail and EVAP pipes in order to prevent possible contamination of the EVAP/fuel system.
6. Raise and suitably support the vehicle. Refer to Vehicle Lifting.




7. Remove the nuts securing the left catalytic converter to the exhaust manifold.




8. Remove the nuts securing the right catalytic converter to the exhaust manifold.
9. Lower the catalytic converter assembly until it rests on the vehicle frame.




10. Use the following procedure if the vehicle is equipped with 2-wheel drive (2WD):

1. Support the transmission with a suitable transmission jack.
2. Remove the transmission support.
3. Lower the transmission slightly.
4. Remove the EVAP/fuel hose/pipe assembly from the retaining clips (1) on the transmission.




11. Use the following procedure if the vehicle is equipped with 4-wheel drive (4WD):

1. Remove the front propeller shaft.
2. Remove the transfer case.
3. Support the transmission with a suitable transmission jack.
4. Remove the transmission support.
5. Lower the transmission slightly.
6. Remove the EVAP/fuel hose/pipe assembly from the retaining clips (1) on the transmission.




12. Remove the EVAP/fuel hose/pipe bracket nut (5).
13. Remove the fuel hose/pipe bracket (6) from the bellhousing stud.




14. Disconnect the EVAP pipe (2) from the fuel tank.
15. Disconnect the fuel feed pipe (1) from the fuel tank.
16. Cap the fuel and EVAP pipes at the fuel tank.
17. Remove the EVAP/fuel hose/pipe assembly from the vehicle.

Important: Note the position of the EVAP/fuel hose/pipe assembly clips prior to disassembly.

18. Remove the EVAP/fuel hose/pipe assembly retaining clips.
19. Remove the fuel feed or return pipe to be replaced from the EVAP/fuel hose/pipe assembly.

Installation Procedure

1. Install the fuel feed or return pipe to the EVAP/fuel hose/pipe assembly.
2. Install the EVAP/fuel hose/pipe assembly retaining clips.




3. Install the EVAP/fuel hose/pipe assembly to the vehicle.
4. Remove the caps from the fuel filter and pipes at the fuel tank.
5. Connect the EVAP pipe (2) to the fuel tank.
6. Connect the fuel feed pipe (1) to the fuel tank.




7. Install the EVAP/fuel hose/pipe bracket (6) to the bellhousing stud.

Notice: Refer to Fastener Notice.

8. Install the EVAP/fuel hose/pipe bracket nut (5).

Tighten the nut to 10 N.m (89 lb in).




9. Use the following procedure if the vehicle is equipped with 4WD:

1. Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission.
2. Raise the transmission to the normal installed height.
3. Install the transmission support.
4. Remove the transmission jack.
5. Install the transfer case.
6. Install the front propeller shaft.




10. Use the following procedure if the vehicle is equipped with 2WD:

1. Install the EVAP/fuel hose/pipe assembly to the retaining clips (1) on the transmission.
2. Raise the transmission to the normal installed height.
3. Install the transmission support.
4. Remove the transmission jack.




11. Install the nuts securing the right catalytic converter to the exhaust manifold.

Tighten the nuts to 50 N.m (37 lb ft).




12. Install the nuts securing the left catalytic converter to the exhaust manifold.

Tighten the nuts to 50 N.m (37 lb ft).

13. Lower the vehicle.




14. Remove the caps from the fuel rail and EVAP pipes.
15. Connect the EVAP canister purge pipe (1, 4).
16. Connect the fuel feed pipe (3) at the fuel rail (2).
17. Install the fuel fill cap.
18. Connect the negative battery cable.
19. Use the following procedure to inspect for leaks:

1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for leaks.