Fuel Supply Line: Service and Repair

Fuel Line Replacement - Chassis

Removal Procedure

Warning

Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

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.

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 (with CH 48027-100) (Service and Repair)Fuel Pressure Relief (w/o CH 48027-100) (Service and Repair).
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
4. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




5. Remove the brake, fuel and EVAP line retainers (1) from the underbody and side rail.
6. Remove the brake, fuel and EVAP line retainers (2) from the underbody studs.
7. Remove the brake line retainers (3) from the underbody side rail.




8. Remove the brake, fuel and EVAP line bundle (1) from the vehicle.




9. Remove the chassis fuel feed line (1) from the retainers.

Installation Procedure




1. Install the chassis fuel feed line (1) to the retainers.




2. Install the brake, fuel and EVAP line bundle (1) to the vehicle.




3. Install the brake, fuel and EVAP line retainers (1) to the underbody and side rail.
4. Install the brake, fuel and EVAP line retainers (2) to the underbody studs.
5. Install the brake line retainers (3) to the underbody side rail.




6. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
7. Connect the chassis EVAP line quick connect fitting (1) to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
9. Use the following procedure in order to inspect for leaks:

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

10. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) (Service and Repair)Fuel Injector Sight Shield Replacement (LCS) (Service and Repair).