Removal/Installation/Cleaning and Inspection Procedure
REMOVAL PROCEDURECAUTION: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair
3. Disconnect the fittings at the engine compartment fuel feed and return pipes (1) and the attaching hardware (2). Be careful not to bend the fuel feed and return pipes (3).
4. Disconnect the fuel pipes (1) and the attaching hardware (2) at the transmission.
5. Disconnect the fuel pipe attaching hardware (1), at the transfer case.
6. Remove the fuel tank.
7. Disconnect the fuel feed and vapor hoses.
8. Remove the hardware (1) retaining the section of pipe to be replaced. Note location of attaching hardware for installation.
9. Remove the section of pipe and hoses.
10. Remove rust or burrs from the engine compartment fuel pipes by the following procedure:
10.1. Use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
10.2. Using a clean shop towel, wipe off the male tube ends.
10.3. Inspect all the connectors for dirt and burrs. Clean or replace the components/assemblies as required.
CLEANING AND INSPECTION PROCEDURE
NOTE: Remove rust or burrs from the engine compartment fuel pipes using the following procedure:
1. Use emery cloth in order to remove rust or burrs from a fuel pipe. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
2. Use a clean shop towel in order to wipe off the male tube ends.
3. Inspect all the connectors for dirt and burrs. Clean or replace the components and assemblies as required.
INSTALLATION PROCEDURE
CAUTION: In order to reduce the risk of fire and personal injury, 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 O-rings on the engine fuel feed and return pipes.
2. Connect the fuel feed and return pipes (3) to the engine fuel pipes (1).
NOTE: Refer to Fastener Notice in Service Precautions.
3. Connect the fuel pipe attaching hardware (2).
Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.
NOTE: Refer to Fastener Notice in Service Precautions.
4. Position the new fuel pipe harness (1) in the original location and the fuel pipe harness attaching hardware (2), tighten to specification.
Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.
NOTE: Refer to Fastener Notice in Service Precautions.
5. Position the new fuel pipe harness in the original location and the fuel pipe harness attaching hardware (1), tighten to specification.
Tighten
Fuel pipe attaching nuts to 27 N.m (20 lb ft) using a back-up wrench.
6. Remove protective caps from one end of both fuel pipes.
Leave 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. Connect the quick-connect fittings at the fuel feed and return pipe near the in-line filter and at the fuel sender assembly.
9. Install the fuel tank and attaching fuel pipe hardware (1).
10. Tighten the fuel filler cap.
11. Connect the negative battery cable.
12. Check for fuel leaks.
12.1. Turn the ignition switch to the ON position for 2 seconds.
12.2. Turn the ignition switch to the OFF position for 10 seconds.
12.3. Again, turn the ignition switch to the ON position.
12.4. Check for fuel leaks.