Fuel Hose and Pipes Sender to Filter

Removal Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel tank. Refer to Fuel Tank Replacement .
4. Remove the quick-connect fittings (1), (4), on the fuel sender assembly-side of the in-pipe fuel filter (3). Refer to Servicing Quick Connect Fittings .
5. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
6. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware and the fuel feed, fuel return, and EVAP pipes.
7. Inspect and note the position of the fuel and EVAP pipes (2) and the fuel and EVAP pipe attaching hardware for installation.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Install the new fuel feed, fuel return, EVAP pipes, and the fuel and EVAP pipe attaching hardware as noted during removal.
2. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
3. Install new plastic connector retainers on the in-pipe fuel filter pipes and on the fuel sender fuel pipes.
4. Install the quick-connect fittings (1) (2). Refer to Servicing Quick Connect Fittings .
5. Install the fuel tank. Refer to Fuel Tank Replacement .



6. Add fuel and install the fuel tank filler pipe cap.
7. Tighten the fuel tank filler pipe cap.
8. Install the negative battery cable.
9. Inspect for leaks.

9.1.	Turn the ignition switch to the On position for 2 seconds.

9.2.	Turn the ignition switch to the Off for 10 seconds.

9.3.	Turn the ignition switch to the On position.

9.4.	Check for fuel leaks.

Fuel Hose and Pipes Filter to Engine - VIN 1

Removal Procedure

Tools Required

J 37088-A , Fuel Pipe Quick-Connect Separator

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
3. Remove the quick-connect fittings in the engine compartment (1), (2). Refer to Servicing Quick Connect Fittings .
4. Raise the vehicle.
5. Remove the quick-connect fitting on the engine-side of the in-line fuel filter fuel return pipe. Refer to Servicing Quick Connect Fittings .
6. Remove the threaded fitting on the engine-side of the in-line fuel filter fuel feed pipe.
7. Cap the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
8. Remove the fuel feed, fuel return, EVAP pipe attaching hardware, and the fuel feed, fuel return, and EVAP pipes.
9. Note the position of the fuel and EVAP pipes, retainer (4), and the fuel and EVAP pipe attaching hardware for installation.
10. Inspect the pipes (5) for bends, kinks and cracks. Repair or replace the pipe or pipes as required.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

1. Install the new fuel feed (1), fuel return (2), EVAP pipe (3), and the fuel and EVAP pipe attaching hardware as noted during removal.
2. Remove the caps from the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
3. Install the new plastic connector retainers on the fuel return pipes.
4. Install the quick-connect fitting at the in-line fuel filter in the fuel return pipe, refer to Servicing Quick Connect Fittings .
5. Install the threaded fitting at the outlet of the in-line fuel filter in the fuel feed pipe.

Tighten
Tighten the in-line fuel filter fitting to 30 N·m (22 lb  ft ).

6. Lower the vehicle.
7. Install the quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings .



8. Add fuel and install the fuel tank filler pipe cap.
9. Tighten the fuel tank filler pipe cap.
10. Install the negative battery cable.
11. Inspect for leaks.

11.1.

Turn the ignition switch to the On position for 2 seconds.

11.2.

Turn the ignition switch to the Off for 10 seconds.

11.3.

Turn the ignition switch to the On position.

11.4.

Check for fuel leaks.

Fuel Hose and Pipes Filter to Engine - VIN K

Removal Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

Notice: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage to the vehicle.

Tools Required

J 37088-A , Fuel Pipe Quick-Connect Separator

1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief .
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
3. Remove the fuel feed (1) and fuel return (4) quick-connect fittings in the engine compartment. Refer to Servicing Quick Connect Fittings .
4. Raise the vehicle.
5. Remove the quick-connect fitting on the engine-side of the in-pipe fuel filter fuel return pipe. Refer to Servicing Quick Connect Fittings .
6. Remove the threaded fitting on the engine-side of the in-pipe fuel filter fuel feed pipe.
7. Cap the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage.
8. Remove the fuel feed, fuel return, EVAP pipe attaching hardware, and the fuel feed, fuel return, and EVAP (fuel purge) pipes.
9. Note the position of the fuel and EVAP pipes (5), retainers, (2) and the fuel and EVAP pipe attaching hardware for installation.
10. Inspect the chassis fuel (3) pipes for bends, kinks and cracks. Repair or replace the pipe or pipes as required.
11. Inspect the retainers. Replace as required.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury:

•	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.)

1. Install the new fuel feed (1), fuel return (4), and EVAP pipes (5) and the fuel and EVAP pipe attaching hardware as noted during removal.
2. Remove the caps from the in-line fuel filter pipe, the fuel feed pipe, and the fuel return pipe.
3. Install the new plastic connector retainers on the fuel return pipes.
4. Install the quick-connect fitting at the in-pipe fuel filter in the fuel return pipe. Refer to Servicing Quick Connect Fittings .
5. Install the threaded fitting at the outlet of the in-pipe fuel filter in the fuel feed pipe.

Tighten
Tighten the in-pipe fuel filter fitting to 30 N·m (22  lb. ft.).

6. Lower the vehicle.
7. Install the quick-connect fittings in the engine compartment, refer to Servicing Quick Connect Fittings .



8. Add fuel and install the fuel tank filler pipe cap.
9. Tighten the fuel tank filler pipe cap.
10. Install the negative battery cable.
11. Inspect for leaks.

11.1.

Turn the ignition switch to the On position for 2 seconds.

11.2.

Turn the ignition switch to the Off for 10 seconds.

11.3.

Turn the ignition switch to the On position.

11.4.

Check for fuel leaks.

Fuel Hose and Pipes EVAP System

Removal Procedure

Notice: Do Not attempt to repair the EVAP pipes or the connecting hoses. Replace the damaged EVAP pipes or the connecting hoses are damaged. If the nylon EVAP pipe becomes kinked and cannot be straightened, it must be replaced.

1. Remove the hardware retaining the EVAP pipe.
2. Note the location of the attaching hardware for installation.
3. Remove the EVAP pipe.
4. Inspect the hoses for cuts, swelling, cracks and distortion. Replace the hoses as required.
5. Inspect the pipes for bends, kinks and cracks. Replace the pipes as required.

Installation Procedure

Notice: Properly secure the EVAP pipe in order to prevent chafing of the pipe.

Important: Route the replacement EVAP pipe in the same manner as the original EVAP pipe was routed.

1. Install the EVAP pipe.
2. Install the hardware retaining the EVAP pipe.