Tools Required

SA9805E Fuel Line Disconnect Set

Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

1. Position the vehicle on the hoist.

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

2. Disconnect the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .




Caution: Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12  in) diameter to adequately catch the fluid.

4. Disengage the front fuel feed and return lines at the fuel rail using the SA9805E .
5. Remove the fuel line bracket bolt.

Important: To facilitate removal, it may be necessary to spray quick connects with penetrating oil to remove debris.

6. Disengage the evaporative emission (EVAP) canister purge line underhood, located near the top of the passenger's side strut tower, using the SA9805E .
7. Remove the lines from the retaining clips.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

8. Raise the vehicle to a comfortable working height.




Caution: Never drain or store fuel in an open container due to the possibility of fire or explosion.

9. Disconnect the front fuel feed, return, and front EVAP canister purge lines from the chassis fuel feed, return, and EVAP canister purger lines located near the passenger front wheel well.
10. Disconnect the front fuel feed, return, and the front EVAP canister purge lines from the chassis fuel feed, return, and the EVAP canister purger lines located near passenger front wheel well.
11. Remove the necessary lines.

Caution: Whenever fuel line connectors are disconnected, lubricate steel line male ends with clean engine oil. Holding the steel line, firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Make sure the fuel line connects are fully seated. Pinched, kinked, or damaged fuel lines must be replaced.

Notice: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

Notice: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

1. Make sure the lines are not kinked, bent, or damaged.
2. Install the fuel and vapor lines. Make sure the lines are properly routed.
3. Attach the fuel line connectors at both ends. Connect the vapor line at both ends.

Notice: Refer to Fastener Notice in the Preface section.





Notice: All nuts that are corroded or damaged must be replaced to ensure fuel line retainers do not come loose from the vehicle's body.

4. Clip the fuel and vapor hoses in place. Install the fuel line bracket and bolt.

Tighten
Tighten the fuel line bracket bolt to 10 N·m (89 lb in).

5. Install the underbody retaining clip. Hammer on the studs with a rubber mallet.
6. Lower the vehicle.
7. Connect the negative battery terminal.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

8. Prime the fuel system.

8.1.	Cycle the ignition ON for 5  seconds and then OFF for 10 seconds.

8.2.	Repeat step 8.1 twice.

8.3.	Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

8.4.	If the engine does not start, repeat steps 8.1-8.4.

9. Run the engine and check the system for leaks.