For 1990-2009 cars

### Removal 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.)

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

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. Disconnect the negative battery cable.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Disconnect the fuel return hose (3) from the fuel return pipe by the fuel tank.
5. Remove the bolt from the fuel feed outlet hose (1) from the fuel feed pipe by the fuel tank.
6. Disconnect the fuel feed outlet hose (2) from the fuel feed pipe by the fuel tank.
7. Disconnect the fuel vapor hose (4) from the fuel vapor pipe by the fuel tank.
8. Remove the bolt and disconnect the fuel feed hose (2) from fuel feed pipe in the engine compartment.
9. Disconnect the fuel return hose (1) from the fuel return pipe in the engine compartment.
10. Disconnect the fuel vapor hose (3) from the fuel vapor pipe in the engine compartment.
11. Remove the ten pipe retaining clamps (2) from the fuel pipes.
12. Remove the fuel pipes (1) from the vehicle underbody.

### Installation Procedure

1. Install the fuel pipes (1) to the underbody.
2. Secure the fuel pipes with ten pipe retaining clamps (2).
3. Connect the fuel vapor hose (3) to the fuel vapor pipe in the engine compartment.
4. Connect the fuel return hose (1) to the fuel return pipe in the engine compartment.
5. Connect the fuel feed hose to the fuel feed pipe (2) in the engine compartment.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Secure the fuel feed hose with one bolt.

Tighten
Tighten the fuel feed hose-to-fuel feed pipe bolt to 45 N·m (33 lb ft).

7. Connect the fuel vapor hose (4) to the fuel vapor pipe by the fuel tank.
8. Connect the fuel feed outlet hose (2) to the fuel feed pipe by the fuel tank.
9. Secure the fuel feed outlet hose with one bolt (1).

Tighten
Tighten the fuel feed outlet hose-to-fuel feed pipe bolt to 45 N·m (33 lb ft).

10. Connect the fuel return hose (3) to the fuel return pipe by the fuel tank.
11. Lower the vehicle.
12. Connect the negative battery cable.
13. Turn the Ignition switch to the ON position and then to OFF to pressurize the fuel system.
14. Check for any fuel leaks, repair as necessary.