Removal Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
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. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. 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.)
Important: Always maintain cleanliness when servicing fuel system components.
- Remove the fuel tank. Refer to Fuel Tank Replacement .
- Disconnect the fuel feed, fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
- Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
- Remove the fuel feed, fuel return, and EVAP pipe attaching hardware.
- Remove the fuel feed, fuel return, and EVAP pipes.
- Note the position of the fuel, and EVAP pipes and the fuel and EVAP pipe attaching hardware for installation.
Installation Procedure
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.
- Reinstall the new fuel feed, fuel return, and EVAP pipes and the fuel and EVAP pipe attaching hardware as noted during removal.
- Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
- Reinstall the fuel feed, fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service .
- Inspect and make sure all of the fuel pipe bundle clips, and fasteners are properly installed.
- Reinstall the fuel tank. Refer to Fuel Tank Replacement .
