For 1990-2009 cars

## Fuel Feed and Fuel Return Lines Rear

### Removal Procedure

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Raise and suitably support the vehicle.
5. Remove the fuel tank. Refer to Fuel Tank Replacement .

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.

6. Disconnect the fuel feed and return lines from the fuel sending unit. Refer to Servicing Quick Connect Fittings .
7. Disconnect the fuel feed line from the quick connect fitting just before the fuel filter. Refer to Servicing Quick Connect Fittings .
8. Disconnect the fuel return line from the quick connect fitting above the fuel filter. Refer to Servicing Quick Connect Fittings .

### Installation Procedure

Caution: In order to reduce the risk of fire and personal injury observe the following items:

• | Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes

• | Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a 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.

• | Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. 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.)

1. Clean any contamination from the male line ends and apply a few drops of clean engine oil.
2. Connect the fuel feed and return lines to the fuel sending unit. Refer to Servicing Quick Connect Fittings .
3. Reinstall the fuel tank. Refer to Fuel Tank Replacement .
4. Connect the fuel feed line at the quick connect fitting just past the fuel filter. Refer to Servicing Quick Connect Fittings .
5. Connect the fuel return line at the quick connect fitting above the fuel filter. Refer to Servicing Quick Connect Fittings .
6. Lower the vehicle.
7. Add fuel to the tank.
8. Tighten the fuel filler cap.
9. Connect the negative battery cable.
10. Crank the engine for a few seconds. Turn off the engine if the engine starts.
11. Check for any fuel leaks.

## Fuel Feed and Fuel Return Lines Center

### Removal Procedure

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Disconnect the negative battery cable.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Raise and suitably support the vehicle.
4. Remove the exhaust system from the manifold to the rear of the vehicle.
5. Remove the right side of the intermediate heat shield.
6. Remove the plastic shield covering the lines.
7. Remove the hardware retaining section of the hose that you are replacing.
8. Lower the rear end assembly. Refer to On-Vehicle Service, Rear Suspension and Drive Axles.
9. Disconnect the right rear brake hose bracket.
10. Disconnect the quick connect fitting above the fuel filter for the fuel return line. Refer to Servicing Quick Connect Fittings .
11. Disconnect the bolt at the fuel filter for the fuel feed line.
12. Disconnect the quick connect fittings to the front lines (on the right side almost in line with the catalytic converter). Refer to Servicing Quick Connect Fittings .
13. Remove the fuel feed and fuel return lines from the vehicle.

### Installation Procedure

1. Remove the protective caps from the replacement lines.
2. Clean any of the contamination from the male line ends and apply a few drops of clean engine oil.
3. Mount the lines to the vehicle and install the mounting hardware.
4. Connect the center fuel feed and return lines to the front lines (on the right side almost in line with the catalytic converter). Refer to Servicing Quick Connect Fittings .
5. Connect the fuel feed line at the fuel filter. Refer to Servicing Quick Connect Fittings .
6. Connect the fuel return line at the quick connect fitting above the fuel filter. Refer to Servicing Quick Connect Fittings .
7. Connect the brake hose bracket.
8. Raise and secure the rear end assembly. Refer to On-Vehicle Service, Rear Suspension and Drive Axles.
9. Install the exhaust heat shield.
10. Install the exhaust system.
11. Lower the vehicle.
12. Connect the negative battery cable.
13. Crank the engine for a few seconds. Turn off the engine if the engine starts.
14. Check for any fuel leaks.
15. Reinstall the plastic shield over the lines if no leaks are present.

## Fuel Feed and Fuel Return Lines Engine Compartment

### Removal Procedure

Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Raise and suitably support the vehicle.
4. Remove the plastic shield over the lines (the underbody center section).
5. Remove the front fuel feed-return lines from the attaching hardware.
6. Pull the fuel feed-return lines through the underbody frame support.
7. Lower the vehicle.
8. Disconnect the fuel lines from the fuel rail.
9. Pull the fuel lines through the fender well and out of the engine compartment.

### Installation Procedure

1. Remove the protective caps from the replacement lines.
2. Install the fuel lines through the fender well from the engine compartment.

Important: Wherever the lines pass through the metal, be sure that the grommets (where used) are installed and in good condition.

3. Clean the contamination, if any, from the male line ends and apply a few drops of clean engine oil.
4. Reconnect the fuel lines to the fuel rail.
5. Raise the vehicle.

Important: Wherever the lines pass through the metal, be sure that the grommets (where used) are installed and in good condition.

6. Feed the lines through the underbody frame support.
7. Reconnect the quick connect fittings to the center section lines (on the right side almost in line with catalytic converter). Refer to Servicing Quick Connect Fittings .
8. Install the retaining hardware.
9. Lower the vehicle.
10. Connect the negative battery cable.
11. Crank the engine for a few seconds. Turn off the engine if the engine starts.
12. Check for any fuel leaks.
13. Reinstall the underbody plastic shield over the lines if no leaks are present.