Fuel Line Replacement - Chassis

Fuel Line Replacement - Chassis

Special Tools

* EN-6015 - Closure Plugs

* EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) Special Tools (Diagnostic Tools).

Removal Procedure

Warning: Refer to Gasoline/Gasoline Vapors Warning Service Precautions.


1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

3. Release the fuel pressure. Refer to Fuel Pressure Relief Service and Repair.




4. Disconnect the fuel feed pipe quick connection (4). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

5. Close the fuel feed pipe with the EN-6015 - plug.

6. Unclip the fuel feed pipe from the fuel vent pipe (2) and the fuel feed pipe bracket (3).

7. Open the upper bulkhead clip (1).

8. Remove the fuel feed pipe from the upper bulkhead clip.




9. Disconnect the fuel feed pipe quick connection (3) from the fuel pump. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

10. Remove the fuel feed pipe bolt (2) from the camshaft cover.

11. Remove the fuel feed pipe (1).

12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Standard) Service and Repair.

13. Remove the underbody front air deflector - right side.




14. Remove and DISCARD the 2 exhaust front hanger bracket bolts (2).

15. Remove and DISCARD the 2 frame reinforcement bolts (2).

16. Loosen the drive train and front suspension frame bolt (3).

17. Remove the front pipe hanger bracket (1).

18. Lower the engine frame approximately 2 inches to allow clearance to release the line clip and routing the pipe past the steering gear and stabilizer shaft.

19. Disconnect the fuel feed pipe from the flexible fuel sensor. Refer to Flexible Fuel Sensor Replacement Flexible Fuel Sensor Replacement.




20. Open the 4 brake and fuel pipe clips (2) at the underbody.

21. Remove the fuel feed pipe (1) from lower bulkhead and underbody.




22. Disconnect the fuel tank feed pipe connector (1) from the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

23. Close the fuel feed pipe and fuel tank feed pipe with the EN-6015 - plugs.

24. Unclip the fuel feed pipe from the rear brake and fuel pipe clip (2).




25. Unclip the fuel feed pipe (1) from the other brake and fuel pipe clips (2).

Note: Do not bend the fuel feed pipe.

26. Remove the fuel feed pipe.

Installation Procedure





Note: Do not bend the fuel feed pipe.

1. Install the fuel feed pipe (1).

2. Clip the fuel feed pipe into the brake and fuel pipe clips (2).




3. Remove the EN-6015 - plugs from the fuel feed tank pipe (1) and the fuel feed pipe (3).

4. Connect the fuel tank feed pipe connector (1) to the fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

5. Install the fuel feed pipe to the rear brake and fuel pipe clip (2) and close the fuel pipe clip.

6. Raise and install the engine frame.




7. Install the drivetrain and front suspension frame support.

8. Install the front pipe hanger bracket (1).

Caution: Refer to Fastener Caution Fastener Caution.

9. Install the NEW drivetrain and front suspension frame bolt (3) and tighten to 160 Nm (118 lb ft).

10. Install the 2 NEW exhaust pipe front hanger bolts (2) - M8 and tighten to 22 Nm (16 lb ft).

11. Install the 2 NEW front suspension support bolts (2) - M10 and tighten in a first pass to 60 Nm (16 lb ft).

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

12. Tighten the 2 front suspension support bolts (2) - M10 in a final pass to additional 30 - 45 degrees, using the EN-45059 - meter.

13. Connect the fuel feed pipe to the flexible fuel sensor. Refer to Flexible Fuel Sensor Replacement Flexible Fuel Sensor Replacement.




14. Install the fuel feed pipe (1) to the lower bulkhead and underbody.

15. Close the brake and fuel pipe clips (2) at the underbody.

16. Install the underbody front air deflector - right side.

17. Lower the vehicle.




18. Install the fuel feed pipe (1).

19. Connect the fuel feed pipe quick connection (3) to the fuel pump. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

20. Install the fuel feed pipe bolt (2) to the cylinder head and tighten to 10 Nm (89 lb in).




21. Remove the EN-6015 - plug.

22. Connect the fuel feed pipe quick connection (4). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

23. Clip in the fuel feed pipe to the fuel vent pipe (2) and the fuel feed pipe bracket (3).

24. Install the fuel feed pipe to the upper bulkhead clip.

25. Close the upper bulkhead clip (1).

26. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

27. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.