Caution: In order to reduce the risk of fire and personal injury observe the following items:

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .



3. Remove the quick-connect fittings (3,4) at the engine compartment fuel feed and return pipes. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
4. Remove the fuel pipe attaching hardward.
5. Remove the air cleaner assembly.
6. Remove the fuel feed and return pipe nuts (2) at the TBI unit (1).
7. Remove the fuel feed and return pipes and the O-rings. Discard the O-rings.
8. Remove the fuel tank if it is necessary to gain access to the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
9. Remove the the quick-connect fittings at the fuel sender assembly. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
10. Remove the hardware retaining section of pipe to be replaced.

Observe the location of the attaching hardware for installation.

Notice: Use an emery cloth in order to remove rust or burrs from the fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.

11. Use an emery cloth in a radial motion with the tube end in order to prevent damage to the O-ring sealing surface.
12. Using a clean shop towel, wipe off male tube ends.
13. Inspect all connectors for dirt and burrs. Clean or replace the components/assemblies as required.
14. Remove the section of pipe and hoses.

1. Install the quick-connect fittings at the fuel feed and return pipes near the in-line filter and at the fuel feed sender assembly. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
2. Install the new O-rings on the engine fuel feed (4) and return (3) pipes.
3. Install the fuel feed and return pipes (2) to the TBI unit (1).

Finger tighten only.

4. Install the fuel pipe attaching hardware.

Tighten
Using a back-up wrench, tighten the fuel pipe attaching nuts to 27 N·m (20 lb ft).

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.

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.)

5. Position the new fuel pipe harness in the original location and fuel pipe harness attaching hardware.
6. Remove the protective caps from one end of both fuel pipes.

Leave the caps on other end of pipes to prevent dirt from entering.

7. Apply a few drops of clean engine oil to the male connector tube ends.
8. Install the quick-connect fittings at the fuel tank sender assembly. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
9. Install the quick-connect fittings at the in-line filter. Refer to Metal Collar Quick Connect Fitting Service and Plastic Collar Quick Connect Fitting Service .
10. Install the fuel tank and the attaching hardware if the tank was removed. Refer to Fuel Tank Replacement .
11. Tighten the fuel filler cap.
12. Connect the negative battery cable.
13. Check for fuel leaks using the following procedure:

13.1.

Turn the ignition switch to ON position for 2 seconds.

13.2.

Turn the ignition switch to OFF for 10 seconds.

13.3.

Turn the ignition switch to ON position.

13.4.

Check for fuel leaks.