Evaporative Emission System Hoses/Pipes Replacement 1500 Series

Removal Procedure

Important: Clean the evaporative emission (EVAP) line connections and surroundings area prior to disconnecting the fittings in order to avoid possible EVAP system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Remove the EVAP purge line (2) from the retaining clips.
3. Disconnect and remove the EVAP vent lines (3) from the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.

Installation Procedure

1. Remove the caps from the fuel feed and EVAP lines.
2. Install and connect the EVAP vent lines (3) to the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Install the EVAP purge line (2) to the retaining clips.
4. Install the fuel tank. Refer to Fuel Tank Replacement .

Evaporative Emission System Hoses/Pipes Replacement 2500 Series - Front Tank

Removal Procedure

Important: Clean the evaporative emission (EVAP) line connections and surroundings areas prior to disconnecting the fittings in order to avoid possible EVAP system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect and remove the EVAP purge line (3) from the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect and remove the EVAP vapor line (1) from the valve and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination.

Installation Procedure

1. Remove the caps from the fuel feed and EVAP lines.
2. Install and connect the EVAP vapor line (1) to the valve and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Install and connect the EVAP purge line (3) to the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

Evaporative Emission System Hoses/Pipes Replacement 2500 Series - Rear Tank

Removal Procedure

Important: Clean the evaporative emission (EVAP) line connections and surroundings areas prior to disconnecting the fittings in order to avoid possible EVAP system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect and remove the EVAP line (1) assembly from the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Cap the EVAP openings in order to prevent possible EVAP system contamination.

Installation Procedure

1. Remove the caps from the EVAP openings.
2. Install and connect the EVAP line (1) assembly to the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Install the fuel tank. Refer to Fuel Tank Replacement .

Evaporative Emission System Hoses/Pipes Replacement 2500 Series - Intermediate

Removal Procedure

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

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Disconnect the fuel pressure sensor electrical connector (1).



4. Disconnect the fuel feed line from the front and rear tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the EVAP lines from the front and rear tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
6. Remove the hose assembly.

Installation Procedure

1. Install the hose assembly.
2. Connect the EVAP lines to the front and rear tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
3. Connect the fuel feed line to the front and rear tank lines. Refer to Plastic Collar Quick Connect Fitting Service .



4. Connect the fuel pressure sensor electrical connector (1).
5. Lower the vehicle.

Evaporative Emission System Hoses/Pipes Replacement 1500 Series - 5.3L (L59) Engine

Removal Procedure

Important: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the fuel feed pipe (4) and return pipe (5) from the sending unit (2). Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect the fuel feed pipe (4) and return pipe (5) from the fuel tank clips (6).
4. Cap the fuel pipes in order to prevent possible fuel system contamination.

Installation Procedure

1. Remove the caps from the fuel pipes.
2. Connect the fuel feed pipe (4) and return pipe (5) to the fuel tank clips (6).
3. Connect the fuel feed pipe (4) and return pipe (5) to the sending unit (2). Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank. Refer to Fuel Tank Replacement .