Caution: Refer to Fuel and Evaporative Emission Pipe Caution in the Preface section.

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

1. Relieve the fuel pressure. Refer to Fuel Pressure Relief .



2. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
3. Slide the PCM off of the studs (5) and position the PCM out of the way.



4. Disconnect the engine coolant temperature sensor electrical connector.

Notice: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice in the Preface section.




5. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
6. Disconnect the EVAP purge pipe (5) from the EVAP canister purge valve.
7. Disconnect the integral clip (3) from the wire harness bracket.



8. Position the fuel feed and return pipes (1) above the PCM studs
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
10. Use the following procedure with two wheel drive (2WD):

10.1.

Remove the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.

10.2.

Lower the transmission slightly.





10.3.

Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission.

10.4.

Disengage the EVAP/fuel hose/pipe assembly from the clip at the rear of the transmission.

11. Use the following procedure with four wheel drive (4WD):

11.1.

Remove the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4 or Transfer Case Assembly Replacement in Transfer Case - NVG 226-NP8 depending on the model of transfer case the vehicle is equipped with.

11.2.

Remove the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.

11.3.

Lower the transmission slightly.





11.4.

Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission.

11.5.

Remove the EVAP/fuel hose/pipe assembly from the clip at the rear of the transmission.




12. Remove the EVAP/fuel hose/pipe assembly (4) from the fuel pipe clip at the rear of the engine.
13. Disconnect the EVAP purge pipe at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



14. Disconnect the chassis fuel return pipe (1) from the fuel tank fuel return pipe. Refer to Plastic Collar Quick Connect Fitting Service .
15. Disconnect the chassis fuel feed pipe (3) from the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
16. Remove the EVAP/fuel hose/pipe assembly.




Important: Note the position of the EVAP/fuel hose/pipe assembly clips before disassembly.

17. Remove the EVAP/fuel hose/pipe assembly retaining clips.
18. Remove the fuel feed (1), fuel return (2), or EVAP purge (3) pipe to be replaced.

1. Place the new fuel feed (1), fuel return (2), or EVAP purge (3) pipe with the remaining pipes in the EVAP/fuel hose/pipe assembly.
2. Install the EVAP/fuel hose/pipe assembly clips as noted during disassembly.
3. Position the EVAP/fuel hose/pipe assembly along the engine and transmission.



4. Connect the chassis fuel feed pipe (3) to the fuel filter.
5. Connect the engine chassis fuel return pipe (1) to the fuel tank fuel return pipe.
6. Connect the EVAP purge pipe at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .



7. Install the EVAP/fuel hose/pipe assembly (4) to the fuel pipe clip at the rear of the engine.
8. Use the following procedure with two wheel drive (2WD):




8.1.	Install the EVAP/fuel hose/pipe assembly into the clip at the rear of the transmission.

Notice: Refer to Fastener Notice in the Preface section.

8.2.	Position the EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission.

Tighten
Tighten the bolt to 3.75 N·m (33 lb in).

8.3.	Raise the transmission to the normal installed position.

8.4.	Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.

9. Use the following procedure with four wheel drive (4WD):




9.1.	Install the EVAP/fuel hose/pipe assembly into the clip at the rear of the transmission.

9.2.	Position the fuel EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission.

Tighten
Tighten the bolt to 3.75 N·m (33 lb in).

9.3.	Raise the transmission to the normal installed position.

9.4.	Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.

9.5.	Install the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 126-NP4 or Transfer Case Assembly Replacement in Transfer Case - NVG 226-NP8 depending on the model of transfer case the vehicle is equipped with.

10. Lower the vehicle.



11. Connect the EVAP purge pipe (5) to the EVAP canister purge valve.
12. Connect the integral clip (3) to the wire harness bracket.
13. Connect the fuel feed (1) and fuel return (2) pipes to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .



14. Connect the engine coolant temperature sensor electrical connector.



15. Install the PCM onto the studs (5).
16. Install the PCM retaining bolts (3).

Tighten
Tighten the bolts to 8 N·m (71 lb in).

17. Install the PCM retaining nuts (6).

Tighten
Tighten the nuts to 8 N·m (71 lb in).

18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Inspect for leaks using the following procedure:

19.1.

Turn ON the ignition, with the engine OFF for 2 seconds.

19.2.

Turn OFF the ignition, for 10 seconds.

19.3.

Turn ON the ignition, with the engine OFF.

19.4.

Inspect for fuel leaks.

20. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement in Frame and Underbody.