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.) |
- Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief
.
- Clean all the fuel pipe connections and areas surrounding the fuel pipe
connections before disconnecting the fuel pipe connections in order to avoid possible
contamination of the fuel system.
- Disconnect the fuel feed and fuel return pipe quick-connect fittings in
the engine compartment. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the evaporative emissions (EVAP) purge pipe at the EVAP canister
purge valve.
- Remove the fuel and EVAP pipes from the retainers.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Disconnect the fuel return pipe quick-connect
fitting (1). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Disconnect the EVAP purge pipe (2) at the EVAP canister.
- Disconnect the threaded fitting from the fuel filter (3) outlet.
- Cap the fuel filter, the fuel feed pipe and the fuel return pipe as needed
in order to stop any fuel leakage.
- Remove
the fuel and the EVAP pipe bundle.
Installation Procedure
- Install
the fuel and the EVAP pipe bundle.
- Remove the caps from the fuel filter, the fuel feed pipe, and the fuel
return pipe.
- Connect the fuel return pipe quick-connect
fitting (1). Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the EVAP purge pipe (2) at the EVAP canister.
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.
- Connect the threaded fitting to the fuel filter (3) outlet. Use a back-up wrench
in order to prevent the fuel filter from turning.
Tighten
Tighten the fuel filter fitting to 30 N·m
(22 lb ft).
- Lower the vehicle.
- Connect
the fuel pipes at the fuel rail. Refer to
Plastic Collar Quick Connect Fitting Service
.
- Connect the EVAP purge pipe at the EVAP canister purge valve.
- Install the fuel and EVAP pipes into the retainers.
- Tighten the fuel tank filler pipe cap.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Inspect for leaks.
| 12.1. | Turn ON the ignition for 2 seconds. |
| 12.2. | Turn OFF the ignition for 10 seconds. |
| 12.3. | Turn ON the ignition. |
| 12.4. | Inspect for fuel leaks. |
- Install the fuel injector sight shield. Refer to
Fuel Injector Sight Shield Replacement
in Engine Mechanical - 3.8L.
