Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

Warning

Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.

Warning

Whenever fuel lines are removed, catch fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch the fluid.

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


Caution: Fuel/Vapor lines cannot be spliced or repaired. The line must be replaced (if damaged) with the same type of line.

1. Relieve the fuel system 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. Disconnect the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).




3. Disconnect the engine compartment fuel hose/pipe (2) from the chassis fuel hose/pipe (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
4. Cap the fuel hose/pipes to prevent contamination and fuel leakage.
5. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




6. Disconnect the chassis fuel hose/pipe (2) from the fuel tank. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
7. Cap the fuel hose/pipes to prevent contamination and fuel leakage.




8. Release the pipe retainers (1) from the vehicle underbody.
9. Remove the fuel hose/pipe from the pipe retainers.
10. Remove the fuel hose/pipe from the vehicle.

Installation Procedure




1. Install the fuel hose/pipe to the vehicle.
2. Install the fuel hose/pipe from the pipe retainers.
3. Attach the pipe retainers (1) to the vehicle underbody.
4. Remove the caps from the fuel pipes.




5. Connect the chassis fuel hose/pipe (2) to the fuel tank. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
6. Lower the vehicle from the hoist.
7. Remove the caps from the fuel pipes.




8. Connect the engine compartment fuel hose/pipe (2) to the chassis fuel hose/pipe (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
9. Connect the negative battery terminal. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
10. Prime the fuel system.

1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat cycling twice.
2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
3. If the engine does not start, repeat steps.

11. Run the engine and check the system for leaks.