Fuel Supply Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis (2500 Series)

Removal Procedure

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




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Disconnect the fuel feed pipe (2) quick connect fitting at the fuel rail.
3. Disconnect the EVAP line (1) quick connect fitting from the chassis line.
4. Cap the fuel rail and EVAP line in order to prevent fuel/EVAP system contamination.
5. Raise and support the vehicle. Refer to Vehicle Lifting.




6. Remove the fuel pipe bracket nut.
7. Remove the fuel pipe bracket from the bellhousing stud.




8. Remove the fuel line clip from the bracket on the automatic transmission.
9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.




10. Remove the fuel line bracket nuts.
11. Remove the fuel/EVAP line bundle.

Installation Procedure




1. Install the fuel/EVAP line bundle.

Notice: Refer to Fastener Notice.

2. Install the fuel line bracket nuts.

Tighten the bolt to 18 N.m (13 lb ft).




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




5. Install the fuel pipe bracket to the bellhousing stud.
6. Install the fuel pipe bracket nut.

Tighten the nut to 20 N.m (15 lb ft).

7. Lower the vehicle.




8. Remove the caps from the fuel rail and EVAP line.
9. Connect the EVAP line (1) quick connect fitting to the chassis line.
10. Connect the fuel feed line (2) quick connect fitting to the fuel rail.
11. Install the fuel fill cap.
12. Connect the negative battery cable.
13. 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.

14. Install the intake manifold sight shield.