Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

Note: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination.




1. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Service and Repair).
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH-48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH-48027)).
3. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
4. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
5. Cap the fuel rail and EVAP pipes.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
7. Remove the transfer case. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement) or Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).




8. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor (2).
9. Remove the engine wiring harness clip (4) from the fuel pipe bracket (3).




10. Remove the transmission and the fuel pipe bracket nut from the bellhousing stud.




11. Remove the fuel line clip from the bracket on the automatic transmission.
12. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
13. Disconnect the range selector cable from the transmission range selector lever. Refer to Range Selector Lever Cable Replacement.
14. Remove the hybrid brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair).




15. Remove the fuel line bracket bolt (3).
16. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
17. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
18. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
19. Remove the fuel/EVAP line clips from the frame and crossmember.
20. Remove the fuel line bracket locator tab from the frame.
21. Remove the fuel/EVAP lines from the vehicle.

Installation Procedure




1. Install the fuel/EVAP lines to the vehicle.
2. Install the fuel line bracket locator tab to the frame.
3. Install the fuel/EVAP line clips to the frame and crossmember.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the fuel line bracket bolt (3).

Tighten the bolt to 12 Nm(106 lb in).

5. Remove the caps from the fuel and EVAP lines.
6. Connect the chassis EVAP line quick connect fitting (4) to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Connect the fuel tank fuel feed line quick connect fitting (5) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
9. Install the fuel line clip to the bracket on the automatic transmission.




10. Install the fuel pipe bracket nut to the bellhousing stud.

Tighten the nut to 20 Nm(15 lb ft).

11. Install the hybrid brake pressure modulator valve. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair).
12. Install the transfer case. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement) or Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).




13. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor (2).
14. Connect the engine wiring harness clip (4) to the fuel pipe bracket (3).
15. Lower the vehicle.




16. Remove the caps from the fuel rail and EVAP line.
17. Connect the engine EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
18. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
19. Install the fuel fill cap.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
21. Use the following procedure in order to inspect for leaks:

1. Turn the ignition ON, with the engine OFF, for 2 seconds.
2. Turn the ignition OFF for 10 seconds.
3. Turn the ignition ON, with the engine OFF.
4. Inspect for fuel leaks.

22. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Service and Repair).