Fuel Filter: Service and Repair
Removal Of Fuel Line Retaining Clip.:
Fuel Filter And Lines.:
NOTE: For replacement of the in-tank filter sock, refer to FUEL PUMP MODULE REPLACEMENT.
REMOVAL
WARNING: Make sure the vehicle is properly supported and squarely positioned prior to lifting. To avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
1. Position vehicle on hoist.
WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.
WARNING: Anytime the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.
2. Disconnect negative battery terminal at battery.
3. Disconnect fresh air inlet hose from rocker/cam cover and remove air inlet tube.
WARNING: whenever fuel line fittings are loosened or disconnected, wrap a shop towel around the fitting to collect fuel. place the cloth in an approved container.
WARNING: Always disconnect the fuel line connection underhood first when changing the fuel filter to relieve pressure that may exist in the line.
WARNING: Always were eye protection and protective clothing when using shop air, chemicals and releasing the fuel line quick connect.
4. Place a shop towel partially around the fuel line quick connect. Using the tool supplied with the fuel filter kit or service tool SA9157E (or equivalent) disengage the large fuel line quick connect located near the intake manifold support brace on the left hand side of vehicle.
NOTE: It may be necessary to clean the female cavity end of the quick connects with a spray penetrate prior to disengaging them.
WARNING: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.
5. Jack or raise the vehicle squarely on a hoist.
6. Disengage the quick connect at fuel filter inlet by pinching the two plastic tangs together and pulling on the fuel supply line.
7. Loosen the fuel filter band clamp fastener. Do not completely remove the nut. Carefully push or pull the fuel filter assembly out of the bracket. Discard the fuel filter in an approved container.
INSTALLATION
1. If the band clamp was removed, clip the fuel return and vapor lines in place and install clamp. Install two new band clamp to the frame rail pal nuts.
^ Torque: 3 Nm (27 in lbs)
WARNING: The inside cavity of the female quick connect (filter inlet) must be cleaned of any foreign debris prior to assembly. Spray the quick connect inner cavity with penetrating oil, while holding the female opening facing downward. Be sure the line is not bent or kinked during cleaning.
2. Install the new snap lock retainer provided into the female quick connect end (filter inlet), if not already installed.
WARNING: The fuel filter return and vapor lines must be properly captured within the fuel filter assembly bracket. The brake lines must remain correctly positioned behind the the mounting bracket attached to the frame rail.
WARNING: When fuel lines are disconnected at quick connectors, lubricate steel line male ends with clean engine oil. Holding steel line, firmly press on female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked or damaged fuel lines must be replaced.
WARNING: Make sure the rubber hose cover on the return line is contained within the filter bracket and seats against the edge of the white fuel return and vapor line clip.
3. Route the filter's nylon outlet line through the band clamp. Insert the filter in the band clamp far enough to allow for fuel line attachment at the engine. Lubricate the engine's steel male inlet end with engine oil. Attach the fuel line and pull back to confirm engagement.
4. Position the filter assembly in the band clamp, insuring the inlet and outlet fuel lines remain properly routed. The filter's upper edge must be located 6.35mm (1/4 in.) from the top of the band clamp.
5. Attach the fuel supply line to the filter. Lubricate the filter's male inlet line with engine oil. Attach the fuel line and pull back to confirm engagement.
6. Tighten the filter band clamp fastener nut and bracket to frame rail if removed.
^ Band Clamps Torque: 10 Nm (89 in lbs)
^ Bracket to frame rail Torque: 3 Nm (27 in lbs)
7. Lower vehicle.
8. Install the air inlet tube and fresh air hose.
9. Connect the negative battery cable.
10. Prime fuel system.
a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.
b. Repeat step 10a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat Steps 10a - 10c.
11. Run the engine and check the system for leaks.