Fuel Hose/Pipes Replacement - Chassis 1500 Series

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.
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.
3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
4. Cap the fuel rail and EVAP pipes.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Unbolt and reposition the front propeller shaft. Refer to Front Propeller Shaft Replacement.



7. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor.



8. Remove the fuel pipe bracket nut from the bellhousing stud.



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



11. Remove the fuel line bracket bolt (3).
12. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service.
13. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
15. Remove the fuel/EVAP line clips from the frame and crossmember.
16. Remove the fuel line bracket locator tab from the frame.
17. Remove the fuel/EVAP lines from the vehicle.

1. Install the fuel/EVAP lines to the vehicle.
2. Install the fuel line bracket locator tab to the frame.
3. Install the fuel/EVAP line clips to the frame and crossmember.

Caution: Refer to Fastener Caution in the Preface section.

4. Install the fuel line bracket bolt (3).

Tighten
Tighten the bolt to 12 N·m (106 lb in).

5. Remove the caps from the fuel and EVAP lines.
6. Connect the chassis EVAP line quick connect fitting (4) to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service.
7. Connect the fuel tank fuel feed line quick connect fitting (5) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.



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



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

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

11. Position and install the front propeller shaft. Refer to Front Propeller Shaft Replacement.



12. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor.
13. Lower the vehicle.



14. Remove the caps from the fuel rail and EVAP line.
15. Connect the engine EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service.
16. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
19. Use the following procedure in order to inspect for leaks:

19.1.

Turn the ignition ON, with the engine OFF, for 2 seconds.

19.2.

Turn the ignition OFF for 10 seconds.

19.3.

Turn the ignition ON, with the engine OFF.

19.4.

Inspect for fuel leaks.

20. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement.

Fuel Hose/Pipes Replacement - Chassis 2500 Series

Note: 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.
2. Disconnect the fuel feed pipe (2) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
3. Disconnect the EVAP line (1) quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
4. Cap the fuel rail and EVAP line in order to prevent fuel/EVAP system contamination.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



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.

1. Install the fuel/EVAP line bundle.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the fuel line bracket nuts.

Tighten
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
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. Refer to Plastic Collar Quick Connect Fitting Service.
10. Connect the fuel feed line (2) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
11. Install the fuel fill cap.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Use the following procedure in order to inspect for leaks:

13.1.

Turn the ignition ON, with the engine OFF, for 2 seconds.

13.2.

Turn the ignition OFF for 10 seconds.

13.3.

Turn the ignition ON, with the engine OFF.

13.4.

Inspect for fuel leaks.

14. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement.