Tracker 4x4 L4-1590cc 1.6L (1993)
Fuel Supply Line: Service and Repair
NOTE: When replacing fuel feed and return pipes, always replace them with original equipment or parts that meet manufacturer's specifications for
those parts. The replacement pipe must have the same type fittings as the original pipes to ensure the integrity of the connection. DO NOT use
copper or aluminum tubing to replace steel tubing. Only tubing meeting the 124M specification or its equivalent is capable of meeting all
pressure and vibration characteristics necessary to ensure durability.
REPLACEMENT
1.
Relieve fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
2.
With the vehicle raised and suitably supported, remove the clamp, and fuel return hose from the fuel return pipe, next to the fuel tank.
3.
Remove the bolt and fuel feed outlet hose from the fuel feed pipe next the fuel tank. Remove the clamp from the fuel vapor hose, and disconnect
the hose from the fuel vapor pipe next to the fuel tank.
4.
Remove the bolt and fuel feed hose from the fuel feed pipe in the engine compartment. Remove the clamp from the fuel return hose in the engine
compartment, and disconnect the hose from the fuel return pipe.
5.
Disconnect the fuel vapor hose from the fuel vapor pipe in the engine compartment. Remove all ten clamps, and the fuel pipes from the underbody
as an assembly.
6.
Install all hoses and pipes in the reverse order they were removed. Torque fittings as follows:
^ Fuel feed hose to pipe bolt 45 Nm (33 lb-ft)
^ Fuel feed outlet hose to fuel feed pipe bolt 45 Nm (33 lb-ft)
7.
Turn the ignition switch ON, then back to LOCK, to pressurize the fuel system, then check for leaks.
REPAIR
When it is impractical to replace an entire fuel line to repair localized damage, use the following guidelines:
^
When rubber hose is used to replace pipe, use only reinforced fuel-resistant hose which is identified with the word "Fluoroelastomer" on the hose.
The inside diameter of the hose must match the outside pipe diameter.
^
DO NOT use rubber hose within 100 mm (4 inches) of any part of the exhaust system, or within 254 mm (10 inches) of the catalytic converter.
^
In repairable areas, cut a piece of hose 100 mm (4 inches) longer than the portion of line removed. If more than a 6 inch length of pipe is removed,
use a combination of steel pipe and hose so that hose lengths will not be more than 254 mm (10 inches).
^
Follow the same routing as the original pipe.
^
Cut the ends of the pipe, remaining on the car, square with a tubing cutter. Using the first step of a double flaring tool, form a bead on the end of
each pipe section. If the pipe is too corroded to withstand the beading operation without damage, the pipe should be replaced. If a new section of
pipe is used, form a bead on both ends of it also.
^
Use a screw type hose clamp. Slide the clamps onto the pipe and push hoses 51 mm (2 inches) onto each portion of the fuel pipe. Tighten the
clamps on each side of the repair.
^
Pipes must be properly secured to the frame to prevent chafing.
