Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure
Warning: Refer to Fuel and Evaporative Emission Pipe Warning (Technician Safety Information).

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


1. Relieve the fuel pressure. Refer to Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).




2. Remove the powertrain control module (PCM) retaining bolts (3) and nuts (6).
3. Slide the PCM (1) off of the studs (5) and position the PCM out of the way.




4. Disconnect the engine coolant temperature sensor electrical connector (1).





Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (Vehicle Damage Warnings).

5. Disconnect the fuel feed pipe (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
6. Disconnect the evaporative emission (EVAP) purge pipe (1) from the EVAP canister purge valve.
7. Disconnect the integral clip (2) from the wire harness bracket.
8. Position the fuel feed pipe (3) above the PCM studs.
9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
10. Use the following procedure with 2-wheel drive (2WD):

1. Remove the transmission support. Refer to Transmission Support Replacement (Transmission Support Replacement).
2. Lower the transmission slightly.




3. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission.
4. Disengage the EVAP/fuel hose/pipe assembly from the clip (1) at the rear of the transmission.

11. Use the following procedure with 4-wheel drive (4WD):

1. Remove the transfer case. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).
2. Remove the transmission support. Refer to Transmission Support Replacement (Transmission Support Replacement).
3. Lower the transmission slightly.




4. Remove the EVAP/fuel hose/pipe assembly retaining bolt (3) from the transmission.
5. Remove the EVAP/fuel hose/pipe assembly (2) from the clip at the rear of the transmission.




12. Remove the EVAP/fuel hose/pipe assembly (4) from the fuel pipe clip at the rear of the engine.
13. Disconnect the EVAP purge pipe at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




14. Disconnect the chassis fuel feed pipe (1) from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
15. Disconnect the chassis EVAP pipe (2) from the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




16. Remove the EVAP/fuel hose/pipe assembly from the vehicle.

Note: Note the position of the EVAP/fuel hose/pipe assembly clips before disassembly.

17. Remove the fuel/EVAP hose/pipe assembly retaining clips.
18. Separate the fuel feed pipe (1) from the EVAP purge pipe (2).

Installation Procedure




1. Position the fuel feed pipe (1) to the EVAP purge pipe (2).
2. Install the EVAP/fuel hose/pipe assembly clips as noted during disassembly.
3. Position the EVAP/fuel hose/pipe assembly along the engine and transmission.




4. Connect the chassis fuel feed pipe (1) to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Connect the chassis EVAP purge pipe (2) to the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




6. Install the EVAP/fuel hose/pipe assembly (4) to the fuel pipe clip at the rear of the engine.
7. Use the following procedure with 2WD:




1. Install the EVAP/fuel hose/pipe assembly into the clip (1) at the rear of the transmission.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Position the EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Tighten the bolt to 3.75 Nm (33 in. lbs.).
3. Raise the transmission to the normal installed position.
4. Install the transmission support. Refer to Transmission Support Replacement (Transmission Support Replacement).

8. Use the following procedure with 4WD:




1. Install the EVAP/fuel hose/pipe assembly (2) into the clip at the rear of the transmission.
2. Position the fuel EVAP/fuel hose/pipe assembly against the transmission and install the retaining bolt (3) through the EVAP/fuel hose/pipe assembly strap into the transmission. Tighten the bolt to 3.75 Nm (33 in. lbs.).
3. Raise the transmission to the normal installed position.
4. Install the transmission support. Refer to Transmission Support Replacement (Transmission Support Replacement).
5. Install the transfer case. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).

9. Lower the vehicle.




10. Connect the EVAP purge pipe (1) to the EVAP canister purge valve.
11. Connect the integral clip (2) to the wire harness bracket.
12. Connect the fuel feed pipe (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




13. Connect the engine coolant temperature sensor electrical connector (1).




14. Install the PCM (1) onto the studs (5).
15. Install the PCM retaining bolts (3) and tighten to 8 Nm (71 in. lbs.).
16. Install the PCM retaining nuts (6) and tighten to 8 Nm (71 in. lbs.).
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
18. Inspect for leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition, for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

19. Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement (Service and Repair).