Removal Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury:
| • | If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. |
| • | When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
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. |
| • | 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 O-rings located
in the female connector will swell and may prevent proper reconnection if
not lubricated.) |
Notice: Do not attempt to straighten any kinked nylon fuel lines.
Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.
Notice: Cap the fittings and plug the holes when servicing the fuel system in
order to prevent dirt and other contaminants from entering the open
pipes and passages.
Important: Always maintain cleanliness when servicing fuel system components.
- Relieve the fuel system fuel pressure. Refer to
Fuel Pressure Relief
.
- Drain the fuel tank. Refer to
Fuel Tank Draining
.
- Remove the fuel tank. Refer to
Fuel Tank Replacement
.
- Remove the fuel feed,
fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly.
Refer to
Metal Collar Quick Connect Fitting Service
.
- Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes
as needed to stop any fuel leakage.
- Remove the fuel feed, fuel return, and EVAP pipe attaching hardware.
- Remove the fuel feed, fuel return, and EVAP pipes.
- Note the position of the fuel, and EVAP pipes and the fuel and
EVAP pipe attaching hardware for installation.
Installation Procedure
Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel
pipes are nicked, scratched or damaged during installation, they must be replaced.
Notice: Always re-attach the fuel lines and fuel filter with all original type
fasteners and hardware.
Do not repair sections of fuel pipes.
Important: If fuel line bundle attaching hardware is damaged or broken replace
it.
- Install the new fuel feed, fuel return, and EVAP pipes and the
fuel and EVAP pipe attaching hardware as noted during removal.
- Remove the caps from the in-pipe fuel filter pipes and the fuel
sender fuel pipes.
- Install the fuel feed,
fuel return, and EVAP pipe quick-connect fittings at the fuel sender assembly.
Refer to
Metal Collar Quick Connect Fitting Service
.
- Install the fuel tank. Refer to
Fuel Tank Replacement
.
- Lower the vehicle.
- Add fuel and install the fuel tank filler pipe cap.
- Tighten the fuel tank filler pipe cap.
- Install the negative battery cable.
- Inspect for leaks.
| 9.1. | Turn the ignition switch to the ON position for 2 seconds. |
| 9.2. | Turn the ignition switch to the OFF for 10 seconds. |
| 9.3. | Turn the ignition switch to the ON position again. |
| 9.4. | Visually inspect the fuel system for fuel leaks. |
