Tools Required
J 37088-A Fuel Line
Disconnect Tool Set
Removal Procedure
Caution: In order to reduce the risk of fire and personal injury observe the
following items:
| • | Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon fuel
pipes |
| • | Do not hammer directly on the fuel harness body clips when installing
new fuel pipes. Damage to the nylon pipes may result in a fuel leak. |
| • | Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. |
| • | Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection and prevent
a possible fuel leak. (During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.) |
Notice: Cap the fittings and plug the holes when servicing the fuel system in
order to prevent dirt and other contaminants from entering the open
pipes and passages.
- Relieve the fuel system
fuel pressure. Refer to
Fuel Pressure Relief
.
- Clean all the engine fuel pipe connections and areas surrounding the
connections before disconnecting the pipes to avoid contamination of the
fuel system.
- Disconnect the fuel feed (1) and the fuel return (5)
quick-connect fittings from the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service
.
- Raise and support the
vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the threaded nut fitting on the fuel filter outlet.
- Disconnect the fuel return pipe quick-connect fitting in front
of the fuel tank. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Cap the in-line fuel filter pipe, the fuel feed pipe, and the
fuel return pipe as needed to stop any fuel leakage.
Important: You may need to partially lower the engine cradle.
- Remove the fuel feed, the fuel return, and the evaporative emission
(EVAP) pipe attaching hardware and the pipes. Note the position of the hardware
for the installation.
- Inspect the pipes for bends, kinks, and cracks.
- Repair or replace the pipes as required.
Installation Procedure
Caution: In order to reduce the risk of fire and personal injury observe the
following items:
| • | Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon fuel
pipes |
| • | Do not hammer directly on the fuel harness body clips when installing
new fuel pipes. Damage to the nylon pipes may result in a fuel leak. |
| • | Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. |
| • | Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection and prevent
a possible fuel leak. (During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.) |
Notice: Always re-attach the fuel lines and fuel filter with all original type
fasteners and hardware.
Do not repair sections of fuel pipes.
Notice:
| • | Secure the fuel pipes to the frame in order to prevent chafing.
Maintain a minimum of 13 mm (½ inch) clearance around
a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm
(¾ inch) around any moving part. |
| • | Do not allow the fuel pipes to come into contact with the fuel
tank or underbody. |
- Install the new fuel feed,
fuel return, and EVAP pipes and the attaching hardware as noted during the
removal.
- Remove the caps from the in-line fuel filter pipe, the fuel feed
pipe, and the fuel return pipe.
- Connect the fuel return pipe quick-connect fitting in front of
the fuel tank. Refer to
Plastic Collar Quick Connect Fitting Service
.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the threaded nut fitting to the fuel filter outlet.
Tighten
Tighten the threaded nut fitting to 30 N·m (22 lb ft).
- Lower the vehicle.
- Connect the fuel feed (1) and the fuel return (2) line
quick-connect fitting to the fuel rail. Refer to
Metal Collar Quick Connect Fitting Service
.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine
Electrical.
- Perform the following procedure to inspect for fuel leaks:
| 8.1. | Turn ON the ignition for 2 seconds. |
| 8.2. | Turn OFF the ignition for 10 seconds. |
| 8.3. | Turn ON the ignition. |
| 8.4. | Inspect for fuel leaks. |
- Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement
in Engine Mechanical 3.5L.
