Service Procedure

1. Verify affected VIN list to vehicle vin.

2. Follow the Inspection and Installation procedures set forth below to complete this safety campaign.

INSPECTION:

3. Park and secure the vehicle, and raise the vehicle on the hoist.








4. Inspect the Fuel Return Hose and Fuel Hose Kit for Lot Number 0707 (Figures 1, 2, 3, and 4).

a. If the inspection determines that neither hose contains Lot Number 0707, lower the vehicle and affix the campaign completion label by following the Applying the Campaign Label section in this bulletin. The campaign is completed for the vehicle.

b. If the inspection determines that either hose contains Lot Number 0707, then only the hose(s) with Lot Number 0707 should be replaced. Follow the appropriate installation instructions to replace the affected hose.

5. Slide Fuel Return Hose Clamps from hose connecting area.

NOTE:
Do not damage or discard the hose clamps. The clamps will be reused.





6. Remove Fuel Return Hose from fuel lines (Figures 1, 5, and 6).

CAUTION:
Place a drain pan underneath Fuel Return Hose and wrap the hose with cloth. Fuel may splash during Fuel Return Hose removal. Use caution when handling fuel.

7. Transfer Fuel Return Hose Clamps from old Fuel Return Hose to new Fuel Return Hose.

8. Install new Fuel Return Hose.

9. If Fuel Return Hose is the only affected hose then skip to Step 26-29. Otherwise continue to Step 10.

FUEL HOSE KIT INSTALLATION

(Includes: High Pressure Hose and Low Pressure Hose)





10. Disconnect the Fuel Hose Kit quick connectors at passenger side of transmission. (Figure 7)





11. Disconnect Oxygen Sensor Harness Clip and remove clip from vehicle. (Figure 8)

NOTE:
Do not damage or discard the Oxygen Sensor Harness Clip. The clip will be revised.





12. Remove 2 transmission mount mounting nuts. (Figure 9)

13. Lower the vehicle from the hoist.

14. Lift the hood and secure in the upright position with the hood prop.





15. Remove the plastic engine cover (Figure 10).





16. Place floor jack with a block of wood under the transmission and jack up the transmission. Measure the gap between the driver side tire and fender. To gain clearance between the engine and the bulkhead at the rear of the engine compartment, the gap between the tire and fender must be at least 210 mm (Figures 11 and 12).

17. Caution:
To prevent injury to the technician and damage to the vehicle, place a pad over the engine and the radiator grille.





18. Using a 90-degree needle nose pliers, remove both fuel hose clamps behind common chamber (Figure 13).

NOTE:
Spraying some silicone fluid on the hose clamps will ease hose clamp removal.





19. Carefully use a blade to cut both high and low pressure hoses to allow for easy removal from the fuel lines (Figure 14).

20. Pull both high and low pressure hoses away from the fuel lines, and discard old Fuel Hose Kit.

21. Install new Fuel Hose Clips on the Fuel Rose Kit and install the new Fuel Hose Kit onto the fuel lines. Then slide Fuel Hose Clips in place to secure the Fuel Hose Kit onto the lines.

22. Lower the floor jack and raise the vehicle on the hoist.





23. Route the other end of the Fuel Hose Kit along the original routing towards the fuel lines. Connect the new quick connectors to the fuel lines (route hoses through two brackets in Figure 15).

NOTE:
Verify Fuel Hose Kit Installation alignment. White mark on Fuel Hose Kit should be in alignment with the top of the metal retaining bracket (Figure 15).

NOTE:
Verify that the quick connectors have been secured by applying a slight tug on each one.

24. Install the Oxygen Sensor Harness Clip.

25. Install the 2 transmission nuts to the specified torque of 30 lb ft.

26. Lower the vehicle from the hoist.

27. Start the engine and inspect each end of the Fuel Hose Kit and the Fuel Return Hose to verify no fuel leak exists.

28. Install the plastic engine cover (Fuel Hose Kit Installation only).

29. Fill out the campaign label.