Fuel Line Replacement - Chassis (1500 Regular Cab)

Fuel Line Replacement - Chassis (1500 Regular Cab)

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. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027).

2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

4. Cap the fuel rail and EVAP pipes.

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .





7. Remove the fuel pipe bracket nut 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 EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.

11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.





12. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

13. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.

15. Remove the fuel line bracket bolt (1).

16. Remove the fuel/EVAP line clip nut (2).

17. Remove the fuel/EVAP line clips from the frame and crossmember.

18. Remove the fuel/EVAP line assembly from the vehicle.

Installation Procedure





1. Position and install the fuel/EVAP line assembly to the vehicle.

2. Install the fuel/EVAP 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/EVAP line bracket bolt (1).

Tighten the bolt to 9 Nm (80 lb in).

5. Install the fuel/EVAP line clip nut (2).

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

6. Remove the caps from the fuel and EVAP lines.

7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.

10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line.





11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.

12. Install the fuel line clip to the bracket on the automatic transmission.





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

Tighten the nut to 25 Nm (18 lb ft).

14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .

15. Lower the vehicle.





16. Remove the caps from the fuel rail and EVAP line.

17. Connect the EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

18. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

19. Install the fuel fill cap.

20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (TP2) Battery Negative Cable Disconnection and Connection (TP2)Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery).

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 Upper Intake Manifold Sight Shield Replacement.