For 1990-2009 cars

## Fuel Hose/Pipes Replacement - Engine Compartment Engine pipes

### Removal Procedure

#### Tools Required

J 37088-A Fuel Pipe Quick-Connect Separator

Notice: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel feed pipe or the engine fuel return pipe.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief .
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.
3. Disconnect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
5. Remove the upper intake manifold assembly. Refer to Intake Manifold Replacement in Engine Mechanical.
6. Disconnect the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.
7. Disconnect the engine fuel feed pipe from the fuel rail. Discard the O-ring.

### Installation Procedure

1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.

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.

2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

Tighten
Tighten the engine fuel pipe fittings to 17 N·m (13 lb ft).

3. Install the upper intake manifold assembly. Refer to Intake Manifold Replacement in Engine Mechanical.
4. Connect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
5. Tighten the fuel fill cap.
6. Inspect for fuel leaks using the following procedure:

6.1. | Turn ON the ignition, for 2 seconds.

6.2. | Turn OFF the ignition, for 10 seconds.

6.3. | Turn ON the ignition.

6.4. | Inspect for fuel leaks.

## Fuel Hose/Pipes Replacement - Engine Compartment Engine Compartment

#### Tools Required

J 37088-A Fuel Pipe Quick-Connect Separator

### Removal 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.)

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 .

Important: Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe connections to avoid possible contamination of the fuel system.

2. Disconnect the quick-connect fittings in the engine compartment. Refer to Metal Collar Quick Connect Fitting Service .
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Cautions and Notices.
4. Disconnect the quick-connect fitting at the front frame rail. Refer to Metal Collar Quick Connect Fitting Service .
5. Cap the fuel feed pipe and the fuel return pipe as needed to stop any fuel leakage.
6. Remove the fuel feed and fuel return pipe attaching hardware and the fuel feed and fuel return pipes.
7. Note the position of the fuel feed and return pipes and the fuel feed and return pipe attaching hardware for installation.
8. Inspect the pipes for bends, kinks and cracks.
9. Replace the fuel pipes if necessary.

### 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. Install the new fuel feed and return pipes and the fuel pipe attaching hardware as noted during removal.
2. Remove the caps from the fuel feed pipe and the fuel return pipe.
3. Install new plastic connector retainers on the fuel pipes.
4. Connect the quick-connect fitting at the front frame rail. Metal Collar Quick Connect Fitting Service
5. Lower the vehicle.
6. Connect the quick-connect fittings in the engine compartment Refer to Metal Collar Quick Connect Fitting Service .
7. Add fuel and tighten the fuel fill cap.
8. Inspect for fuel leaks using the following procedure:

8.1. | Turn ON the ignition, for 2 seconds.

8.2. | Turn OFF the ignition, for 10 seconds.

8.3. | Turn ON the ignition.

8.4. | Inspect for fuel leaks.