Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure





1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027-100) (Fuel Pressure Relief (With CH 48027-100))Fuel Pressure Relief (Without CH 48027-100) (Fuel Pressure Relief (Without CH 48027-100)).
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
3. Remove the fuel feed pipe clip nut (2) from the intake manifold stud.
4. Disconnect the fuel feed pipe (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
5. Disconnect the evaporative emission (EVAP) pipe (3) quick connect fitting from the EVAP purge solenoid. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
6. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.




7. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash.
8. Remove the brake pipes from the clips.
9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service Intervals).




10. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
11. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
12. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination.




13. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs.
14. Remove the brake pipes from the retainers.
15. Remove the fuel feed/EVAP pipe assembly from the vehicle.
16. Place the pipe assembly on a work bench.
17. Open and remove the upper fuel feed/EVAP pipe retainer (3).
18. Open and remove the front of dash fuel feed/EVAP pipe retainers (4).
19. Open and remove the underbody retainers (5).
20. Replace any retainers as necessary.



Installation Procedure





1. Install and close the underbody retainers (5).
2. Install and close the front of dash fuel feed/EVAP pipe retainers (4).
3. Install and close the upper fuel feed/EVAP pipe retainer (3).
4. Position the fuel feed/EVAP pipe assembly to the vehicle.
5. Install the brake pipes to the retainers.
6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs.




7. Remove the caps from the chassis fuel and EVAP pipes.
8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
10. Lower the vehicle.




11. Install the brake pipes to the clips.
12. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.




13. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
14. Connect the EVAP pipe (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
15. Connect the fuel feed pipe (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).

Notice: Refer to Fastener Notice (Fastener Notice).

16. Install the fuel feed pipe clip nut (2) to the intake manifold stud.

Tighten the nut to 10 N.m (89 lb in).

17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LAT) (Service and Repair)Battery Negative Cable Disconnection and Connection (LZ4/LY7) (Service and Repair).
19. Tighten the fuel fill cap.
20. Inspect for leaks.

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