Service Procedure
Fuel Hose/Pipes Replacement ProcedureCAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
CAUTION
Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
CAUTION
Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
1. Relieve the fuel system pressure.
A. Turn ignition OFF.
CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
B. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine.
^ Turn OFF all the lamps and the accessories.
^ Make sure the ignition switch is in the OFF position.
^ Disconnect the battery negative cable from the battery (2).
C. Loosen the fuel filler cap to relieve the fuel tank vapor pressure.
D. Remove the cap from the fuel pressure service port.
CAUTION
Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete.
NOTICE
Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
^ The fuel pipe connections
^ The hose connections
^ The areas surrounding the connections
E. Connect the SA9127E Gage Bar Set to the fuel pressure service port connection.
^ Connect Gage Bar (53476) to Fuel Gage Pressure Adapter (309725) using a flexible hose from Gage Bar Set (SA9127E).
^ Make sure needle valve on Fuel Gage Pressure Adapter (309725) is closed (OFF).
NOTICE
Do not use any tools to tighten the adapter to the fuel pressure service port. If the adapter will not seal with finger tightening, then the seal is defective or damaged and needs to be replaced. Excessive torque on the adapter will damage the fuel pressure service port.
^ Connect Fuel Gage Pressure Adapter (309725) to fuel pressure service port connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage.
CAUTION
Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.
F. Place the bleed hose of the SA9127E into an approved fuel container.
G. Open the bleed valve on the SA9127E in order to bleed the fuel system pressure. The fuel connections are now safe for servicing.
H. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage.
J. Disconnect the SA9127E from the fuel pressure service port connection.
J. Drain any fuel remaining in the gage into an approved fuel container.
K. Install the cap to the fuel pressure service port.
2. Remove Powertrain Control Module (PCM) from bracket and set aside. (Do not disconnect electrical connectors).
3. Remove Underhood Bussed electrical Center (UBEC).
4. Remove UBEC plastic base.
5. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. Refer to Steps 5.A - 5.F for instructions for disconnecting quick connect fittings (metal collar).
CAUTION
Wear safety goggles when using compressed air, as flying dirt particles may cause eye injury.
^ Remove the retainer from the quick-connect fitting.
A. Blow dirt out of the fitting using compressed air.
B. Choose the correct tool from J 37088-A or J41769-1 (blue). Insert the tool into the female connector, then push inward to release the locking tabs.
^ Pull the connection apart.
NOTICE
If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the 0-ring sealing surface. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
C. Using a clean shop towel, wipe off the male pipe end.
D. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
6. Use two open-end wrenches to disconnect the fuel feed pipe.
7. Remove the fuel feed pipe fasteners located on the engine.
8. Disconnect brake vacuum booster line at throttle body.
9. Disconnect canister purge pipe.
10. Disconnect both vacuum lines from supercharger boost solenoid.
11. Remove the engine fuel feed pipe.
Installation Procedure
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 damping 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.
1. Install the new fuel feed pipe to the fuel rail.
Tighten
Tighten the fuel rail to the fuel feed pipe to 14 Nm (10 lb-ft).
2. Install the engine fuel feed pipe fasteners located on the engine.
Tighten
Tighten the fuel feed pipe fastener to 10 Nm (89 lb-in).
3. Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer to Steps 3A - 3D for instructions for connecting quick connect fittings (metal collar).
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 0-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
A. Apply a few drops of clean engine oil to the male pipe end.
B. Push both sides of the fitting together to cause the retaining tabs to snap into place.
C. Once installed, pull on both sides of the fitting to make sure the connection is secure.
D. Install the retainer to the quick-connect fitting.
4. Install canister purge pipe.
5. Install brake booster line to throttle body.
6. Install both supercharger boost control vacuum lines to solenoid.
7. Install UBEC plastic base and UBEC.
8. Position PCM to bracket and install PCM.
9. Connect the negative battery cable.
Important
Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal.
^ Connect the battery negative cable to the battery (2).
Tighten
Tighten the battery cable bolt to 17 Nm (13 lb-ft).
A. Reset the clock.
10. Inspect for leaks using the following procedure:
^ With the engine OFF, turn ON the ignition for 2 seconds.
A. Inspect for fuel leaks.
B. Turn the ignition OFF.
C. With the engine OFF, turn ON the ignition for 2 seconds.
D. Inspect for fuel leaks.
E. Turn the ignition OFF.