B. Replace Corroded Tube(s) and Install Retaining Clip

Note:
Only those tubes with RED CORROSION, as determined by the inspection in section "A" require replacement. Tubes with white powder or other residue/discoloration do not require replacement. The brake tubes are the most susceptible to corrosion. Very few fuel vapor tubes and even fewer fuel supply tubes are expected to require replacement. Therefore, the following procedure replaces brake tubes, then if necessary, the fuel vapor and supply tubes.

1. Lower vehicle from the hoist.

2. Remove air inlet tube, air cleaner housing and coolant over flow bottle.

3. Remove brake lamp fuse from the Power Distribution Center (PDC).

4. Install a brake pedal fixture tool to keep the master cylinder in the applied position, such as an alignment tool or prop rod from the brake pedal to the drivers seat.

Note:
Keeping the master cylinder in the "applied" position makes bleeding the brakes faster and easier since only the REAR brakes will require bleeding.

5. Disconnect the left rear and right rear brake tubes from the:

^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or;

^ proportioning valves on the Hydraulic Control Unit (HCU) on ABS equipped vehicles.

Caution:
Be sure to disconnect only the REAR brake tubes or the entire brake system must be bled.

6. Remove tubes from dash panel rubber and plastic retainers and if equipped, cut tie straps retaining ABS wiring.

Note:
To assure that wiring and tubes are properly positioned during reassembly, note tie strap locations and each tubes position in each retainer.

7. If fuel supply tube requires replacement, release fuel system pressure, then disconnect fuel tube from engine compartment fuel hose quick-connect.

8. Raise vehicle on hoist.

9. Remove the splash shield located at fuel tank sending unit and fuel filter.

10. Disconnect fuel vapor tube from rear hose and allow rear end of tube to drop.

11. Remove bolt retaining fuel filter and lower fuel filter.

12. Disconnect fuel tank sending unit wiring connector.





13. Position transmission jack under fuel tank and remove fuel tank support strap bolts (Figure 4).

Caution:
It is not necessary to drain the fuel tank. However, make sure that jack-to-tank contact surface is adequate and that jack is properly positioned.

14. Slowly lower fuel tank about 2 inches and move tank rearward about two inches (Figure 4).

Caution:
DO NOT lower or move the tank rearward more than two inches or damage to fuel system components or sheet metal at fuel filler tube may occur.

15. Disconnect rear brake tubes from all under body plastic clips.

Note:
Leave clips attached to body. Clips may break if removal is attempted.





16. Disconnect left and right rear brake tubes from the brake hoses at the rear frame rails. Remove and discard the corroded brake tube(s) (Figure 5).

Note:
To ease tube removal, the left tube should first be moved inboard of fuel supply and vapor tubes, then lowered.

17. If fuel vapor tube requires replacement, disconnect tube from front vapor hose. Remove and discard corroded vapor tube.

18. If fuel supply tube requires replacement, disconnect tube from fuel filter quick-connect. Remove and discard corroded supply tube.

19. If fuel supply tube required replacement, feed front of new tube into position in the engine compartment, then attach rear of tube to the fuel filter quickconnect.

20. If fuel vapor tube required replacement, feed front of new tube into position, but do not connect to either hose.

21. Feed front of new left brake tube into position, then attach the rear of the tube to the three retaining clips forward of the fuel tank and to the clip at the left rear brake hose.

Note:
ABS wiring must be clipped to the top frame clip positions.

22. Feed front of right brake tube into position, then attach the rear of the tube to the retaining clip at the right rear brake hose.

Note:
ABS wiring must be clipped to the top clip position. Also, make sure fourway oxygen sensor connector and wiring (located at generator) is routed inboard of all brake and fuel tubes.

23. If fuel vapor tube required replacement, attach front of vapor tube to the front vapor hose and attach tube to bottom clip position (right front brake tube should be in top clip position).

24. Transfer any retaining clips from old tubes to new ones and attach all tubes to all remaining underbody retaining clips. The left rear brake tube must be in the inboard clip position with the fuel supply (largest tube) next to it. The right rear brake tube must be in the outboard clip position with the fuel vapor tube next to it. The ABS wiring, if equipped, must be attached outboard of the tubes.

25. Reinstall the two outboard bolts into the frame rail and crossmember holes and torque to 250 in-lbs (28 N.m) (Figure 3)

Note:
The two outboard bolts must be installed to assure the structural integrity of the frame rail.

26. Snap the provided clip onto the four tubes so that the nipple on bottom of clip is in the outboard position. The clip should be positioned at the forward edge of the center crossmember as shown in figure 3.

27. Using the screw hole in the clip as a template, center punch, then drill a 3/16 inch (4.8 mm) hole in the crossmember for the clip retaining screw (Figure 3).

28. Secure clip to the crossmember and torque the provided retaining screw to 30 in-lbs (3 N.m) (Figure 3).

29. Attach left and right rear brake tubes to rear brake hoses and torque fittings to 145 in-lbs (17 N.m) (Figure 5).

30. Raise fuel tank into position. Install two fuel tank support straps and torque fuel tank strap bolts to 250 in-lbs. (28 N.m).

31. Attach rear end of vapor tube to the vapor hose at the fuel tank.

32. Attach fuel tank sending unit wiring connector.

33. Install fuel filter and torque fuel filter mounting bolt to 85 in-lbs. (10 N-m).

34. Install splash shield at fuel tank sending unit and fuel filter.

35. Lower vehicle from hoist.

36. Install all tubes into dash panel rubber and plastic retainers. Be sure to position each tube in the retainers as previously noted. If equipped, secure ABS wiring to tubes with the provided tie straps at the previously noted locations.

Note:
If necessary, verify proper tube position by comparing the vehicle to another PL vehicle of the same tube configuration (ie: ABS vs. NON-ABS).

37. Install the left rear and right rear brake tubes to the:

^ proportioning valves on the inboard side of master cylinder on NON-ABS equipped vehicles or;

^ proportioning valves on the HGU on ABS equipped vehicles. Torque fittings to 145 in-lbs (17 N.m).

38. If the fuel supply tube was replaced, the engine compartment fuel hose to the fuel rail must also be replaced. Install the provided SOHG (pn 4546923) or DOHG (pn 4546954) fuel hose from the fuel rail to the supply tube as appropriate.

Note for early built PL vehicles: The engine compartment end of the provided fuel supply tube terminates at a different angle than the OEM tube. As a result, the provided fuel supply hose will have a different shape than the OEM hose.

39. Install coolant overflow bottle.

40. Install air cleaner housing and air inlet duct.

41. Fill the master cylinder reservoir with clean brake fluid conforming to DOT 3 specifications.

42. Remove the brake pedal fixture and install the brake lamp fuse into the PDC.

43. Bleed the rear brakes.

44. With the engine running and holding firm pressure on the brake pedal, inspect the brake and fuel system to verify that no brake fluid or fuel leaks exist.

45. Road test vehicle to assure proper operation.