Fuel Supply Line: Service and Repair

FUEL LINES

Exploded View

Part 1:

Part 2:

Removal

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.
- 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.
- 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.
- 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.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the fuel tube-to-fuel rail spring lock coupling.
4. Disconnect the evaporative emissions (EVAP) canister vapor tube-to-EVAP canister purge valve quick connect coupling.

5. NOTE: LH side shown, RH side similar.

If equipped, remove the transfer case skid plate and bolts.







6. If equipped, remove the front driveshaft.
7. Disconnect the fuel tube-to-fuel filter outlet tube spring lock coupling.
8. Disconnect the EVAP canister vapor tube-to-EVAP canister quick connect coupling.
9. If equipped, remove the selector lever heat shield.







10. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.







11. Remove the selector lever bracket bolts and remove the bracket.







12. Remove the fuel tube and vapor tube from the bracket at the transmission bellhousing.
13. Disconnect the LH catalyst monitor sensor electrical connector.
14. Remove the catalyst monitor sensor electrical connector wiring pushpin from the fuel tube and vapor tube bracket at the rear of the transmission housing.
15. Remove the vapor tube and fuel tube from the bracket at the rear of the transmission housing.
16. Remove the EVAP canister-to-EVAP purge valve vapor tube from the vehicle.
17. Remove the fuel filter-to-fuel rail tube from the vehicle.

Installation
1. Position the fuel filter-to-fuel rail tube in the vehicle.
2. Position the EVAP canister-to-EVAP purge valve vapor tube in the vehicle.
3. Install the fuel tube and vapor tube into the bracket at the transmission bellhousing.
4. Install the fuel tube and vapor tube into the bracket at the rear of the transmission housing.
5. Install the catalyst monitor sensor electrical connector wiring pushpin into the fuel tube and vapor tube bracket at the rear of the transmission housing.
6. Connect the catalyst monitor sensor electrical connector.
7. Install the selector lever bracket and bolts.
- Tighten to 48 Nm (35 lb-ft).







8. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked in the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed.

With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud and move the locking tab downward into the locked position.
- Listen for the audible click.
- Pull back on the selector lever cable to make sure it is correctly installed.







9. If equipped, install the selector lever heat shield.







10. Connect the fuel tube-to-fuel filter outlet spring lock coupling.
11. Connect the EVAP canister vapor tube-to-EVAP canister quick connect coupling.
12. If equipped, install the front driveshaft.

13. NOTE: LH side shown, RH side similar.

If equipped, install the transfer case skid plate and bolts.
- Tighten to 25 Nm (18 lb-ft).







14. Connect the fuel tube-to-fuel rail spring lock coupling.
15. Connect the EVAP canister vapor tube-to-EVAP purge valve quick connect coupling.