Fuel Supply Line: Service and Repair

Fuel Feed Pipe Replacement

Removal Procedure

Warning:
Refer to Gasoline/Gasoline Vapors Warning Service Precautions


Warning:
Refer to Safety Goggles and Fuel Warning Safety Goggles and Fuel Warning


Warning

In order to reduce the risk of fire and personal injury observe the following items:

* Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

* Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.

* Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.

* Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection





2. Unclip the fuel feed pipe (2) from the fuel feed pipe clip (3).

3. Release the fuel feed pipe (2) from the multiport fuel injection fuel rail (1) and remove the fuel feed pipe.

4. Close the fuel feed pipe and the fuel rail with a suitable cap.





5. Open the upper bulk head clip (2).

6. Remove the fuel feed pipe (1) from the upper bulkhead clip.

7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair





8. Remove and DISCARD the exhaust front hanger bracket bolt (3).

9. Remove and DISCARD the frame reinforcement bolt (2).

10. Loosen the drive train and front suspension frame bolt (1).





11. Rotate the right frame reinforcement (1) to a position shown to get access to the fuel pipes.





12. Open the 4 fuel pipe clips (2).

13. Remove the lower bulk head clip.





14. Disconnect the fuel tank feed pipe connector (1) from fuel feed pipe (4). Refer to Plastic Collar Quick Connect Fitting Service Service and Repair

15. Close the fuel feed pipe and fuel tank feed pipe with suitable caps.

16. Disconnect the wiring harness plug (2).

17. Open the fuel pipe clip (3) and remove the fuel feed pipe (4).

18. Close the fuel pipes with suitable caps.

Installation Procedure





1. Remove the caps from the fuel feed tank pipe and from the fuel feed pipe.

2. Install the fuel feed pipe (4) and close the fuel pipe clip (3).

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

4. Connect the wiring harness plug (2).





5. Install the lower bulk head clip.

6. Close the 4 fuel pipe clips (2).





7. Rotate the right frame reinforcement to its original position.

8. Install the exhaust front hanger bracket bolt (3).

9. Install the frame reinforcement bolt (2).

Caution:
Refer to Fastener Caution Fastener Caution

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

10. Tighten the NEW exhaust front hanger bracket bolt (3) to 22 Nm (16 lb ft).

11. Tighten the NEW frame reinforcement bolt (2) to 60 Nm (44 lb ft).

12. Tighten the drivetrain and front suspension frame bolt (1) to 160 Nm (118 lb ft).

13. Lower the vehicle.





14. Install the fuel feed pipe (1) to the upper bulkhead clip.

15. Close the upper bulk head clip (2).





16. Remove the caps from the fuel feed pipe (2) and from the multiport fuel injection fuel rail (1).

17. Install the fuel feed pipe (2) to the multiport fuel injection fuel rail (1).

18. Clip in the fuel feed pipe (2) to the fuel feed pipe clip (3).

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