For 1990-2009 cars

### 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.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel tank (1). Refer to Fuel Tank Replacement .
4. 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 .
5. Cap the fuel sender fuel pipes and the in-line fuel filter pipes as needed to stop any fuel leakage.
6. Remove the fuel feed, fuel return, and EVAP pipe attaching hardware and the fuel feed, fuel return, and EVAP pipes.
7. 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.

1. Install the new fuel feed, fuel return, EVAP pipes, and the fuel and EVAP pipe attaching hardware as noted during removal.
2. Remove the caps from the in-line fuel filter pipes and the fuel sender fuel pipes.
3. Install new plastic connector retainers on the in-line fuel filter pipes and on the fuel sender fuel pipes.
4. Install the quick-connect fittings (1), (4). Refer to Plastic Collar Quick Connect Fitting Service .
5. Install the fuel tank (1). Refer to Fuel Tank Replacement .
6. Add fuel and install the fuel tank filler pipe cap.
7. Tighten the fuel tank filler pipe cap.
8. Install the negative battery cable. Refer to Battery Cable in Engine Electrical.
9. 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.

9.4. | Check for fuel leaks.

10. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement in Body and Accessories.