Fuel Supply Line: Service and Repair

FUEL FEED LINE/EVAP CANISTER PURGE LINE

The fuel feed line and the EVAP canister purge line are routed together on the underbody up to the fuel rail. The two lines are serviced as an assembly.

Removal
1. Position vehicle on hoist

CAUTION: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER THE ENGINE IS SHUT DOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM.




2. Relieve pressure in fuel system at fuel pressure test port (refer to "Relieving Fuel Pressure").




3. Remove retaining screw (10 mm hex) at fuel line clip to the intake manifold brace.

NOTE: To prevent fuel from draining out of the fuel rail, install a soft plastic or vinyl cap (3/8" I.D.) over the fuel rail connection.

4. Disconnect fuel feed line at fuel rail and EVAP canister purge line at purge solenoid (both are quick connects).

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. MAKE SURE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.

IMPORTANT: Purge solenoid connection may be more accessible from under vehicle.

5. Raise vehicle to a comfortable working height.

CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR REMOVED, WRAP A SHOP CLOTH AROUND THE FITTING AND HAVE AN APPROVED CONTAINER AVAILABLE TO COLLECT ANY FUEL.




6. Disconnect 90° fuel feed line quick connect at the outlet of fuel filter/pressure regulator.
7. Disconnect 90° EVAP canister purge line quick connect at front edge of fuel tank.
8. Remove (4) attachment screws (10 mm hex) and remove fuel/brake line shield on underbody.




9. Remove all (6) attachment nuts (10 mm hex) securing fuel/purge line bundle retainer clips to underbody and remove clips from brake lines.
10. Open retainer clip at left-hand body side rail and remove fuel and purge line.
11. Remove fuel/purge line bundle from vehicle.

Installation




1. Load fuel/purge line bundle (with retaining clips attached) to underbody from under vehicle.
2. Compare position of retaining clips on lines to attachment stud location on underbody and adjust position of clips as necessary.
3. Install retaining clips to brake lines and attachment studs with nuts (10 mm hex).

Torque:
Brake Line Retaining Clip: 2.5 N.m (22 in-lbs)

4. Install fuel and brake line shield to underbody with (4) attachment screws (10 mm hex).

Torque:
Fuel Line Shield-to-Underbody: 12 N.m (9 ft-lbs)

NOTE: Replace the plastic fuel line retainers whenever the fuel supply lines are disconnected at the fuel filter/pressure regulator and fuel rail. Install the new retainer into the female portion of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female connection. Firmly press the male and female portions together until a click is heard, then pull firmly back to confirm engagement.

5. Connect fuel supply line to filter/regulator outlet and chassis purge line to fuel tank purge line.
6. Connect chassis purge line to EVAP canister purge solenoid.




7. Install forward fuel line retaining clip to intake manifold brace with attachment screw (10 mm hex).

Torque:
Fuel Line Retainer Clip: 4 N.m (35 in-lbs)

8. Connect fuel feed line to fuel rail.
9. Energize fuel pump and check all connections for leaks.
10. Perform the "Service Bay Diagnostic Test" for the evaporative emission system using the Scan tool. This test will verify the integrity of the vapor handling areas of the fuel system.