Removal Procedure
Tools Required
J 34730 Fuel Pressure Gauge
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.
- Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Remove the fuel tank (1). Refer to Fuel Tank Replacement .
- Remove the quick-connect fittings (1), (4), on the fuel sender assembly-side of the in-line fuel filter (3). Refer to Plastic Collar Quick Connect Fitting Service .
- Cap the fuel sender fuel pipes and the in-line fuel filter pipes as needed to stop any fuel leakage.
- Remove the fuel feed, fuel return, and EVAP pipe attaching hardware and the fuel feed, fuel return, and EVAP pipes.
- Inspect and note the position of the fuel and EVAP pipes (2) 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,
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.
- Install the new fuel feed, fuel return, EVAP pipes, and the fuel and EVAP pipe attaching hardware as noted during removal.
- Remove the caps from the in-line fuel filter pipes and the fuel sender fuel pipes.
- Install new plastic connector retainers on the in-line fuel filter pipes and on the fuel sender fuel pipes.
- Install the quick-connect fittings (1), (4). Refer to Plastic Collar Quick Connect Fitting Service .
- Install the fuel tank (1). Refer to Fuel Tank Replacement .
- Add fuel and install the fuel tank filler pipe cap.
- Tighten the fuel tank filler pipe cap.
- Install the negative battery cable. Refer to Battery Cable in Engine Electrical.
- Inspect for leaks.
- Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.
| 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. |
| 9.4. | Check for fuel leaks. |
