Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Remove the fuel injector sight shield.
3. Remove the intermediate steering shaft.
4. Disconnect the fuel feed pipe (2) quick connect fitting from the fuel rail.
5. Disconnect the evaporative emission (EVAP) pipe (3) quick connect fitting from the EVAP purge solenoid.
6. Cap the fuel rail and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.




7. Raise and support the vehicle. Refer to Vehicle Lifting.
8. Disconnect the fuel pump fuel feed pipe quick connect fitting (6) from the chassis fuel feed pipe.
9. Disconnect the EVAP canister vent front pipe quick connect fitting (5) from the chassis EVAP pipe.
10. Remove the fuel feed/EVAP pipe assembly clip (1) from the body.
11. Remove the fuel feed/EVAP pipe assembly clip nut (3) and clip (2) from the stud.
12. Loosen the fuel feed/EVAP pipe clip (4) bolt, and remove the fuel feed/EVAP pipe assembly from the vehicle.

Installation Procedure






Notice: Refer to Fastener Notice.

1. Position the fuel feed/EVAP pipe assembly to the vehicle, and tighten the fuel feed/EVAP pipe clip (4) bolt.

Tighten the bolt to 8 N.m (71 lb in).

2. Install the fuel feed/EVAP pipe clip (2) and nut (3) to the stud.

Tighten the nut to 9 N.m (80 lb in).

3. Install the fuel feed/EVAP pipe clip (1) to the body.
4. Connect the EVAP canister vent front pipe quick connect fitting (5) to the chassis EVAP pipe.
5. Connect the fuel pump fuel feed pipe quick connect fitting (6) to the chassis fuel feed pipe.
6. Lower the vehicle.




7. Remove the caps from the fuel rail and the EVAP purge solenoid.
8. Connect the EVAP pipe (3) quick connect fitting to the EVAP purge solenoid.
9. Connect the fuel feed pipe (2) quick connect fitting to the fuel rail.
10. Tighten the fuel fill cap.
11. Use the following procedure in order to inspect for leaks:

* Turn the ignition ON, with the engine OFF, for 2 seconds.
* Turn the ignition OFF for 10 seconds.
* Turn the ignition ON, with the engine OFF.
* Inspect for fuel leaks.

12. Install the intermediate steering shaft.
13. Install the fuel injector sight shield.