Tools Required

J 41416 Ultrasonic Leak Detector

Caution: Natural gas is highly flammable. In order to reduce the risk of fire and personal injury, keep sparks, flames, and smoking materials away from the vehicle while you perform the Compressed Natural Gas (CNG) fuel system service.

Caution: The Compressed Natural Gas (CNG) system operates at pressures up to 24820 kpa (3600 psi). Relieve the CNG fuel system pressure before servicing CNG fuel system components in order to reduce the risk of fire and personal injury.

1. Relieve the CNG fuel system pressure. Refer to Fuel Pressure Relief .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cable.
3. Remove the fuel line clip.
4. Disconnect the fuel line from the high pressure regulator (HPR) (1).



5. Disconnect the fuel line from the intake manifold union (1). Discard the O-ring face seal.
6. Remove the wire harness bracket nut.
7. Remove the HPR to intake manifold union fuel line (2).

1. Install the HPR to intake manifold union fuel line (2).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the wire harness bracket nut.

Tighten
Tighten the wire harness bracket nut to 9.5 N·m (84 lb in).

Caution: Natural gas is stored under high pressure. If a leak occurs, the high pressure could cause a personal injury. In order to prevent Compressed Natural Gas (CNG) fuel leaks, always replace the CNG fuel system O-rings during service.

3. Connect the fuel line to the intake manifold union using a new O-ring face seal (1). Lubricate the new O-ring face seal with petroleum jelly or equivalent.

Tighten
Tighten the fuel line fitting to 37 N·m (27 lb ft).




4. Connect the fuel line to the HPR (1).

Tighten
Tighten the fitting to 15 N·m (11 lb ft).

5. Install the fuel line clip.
6. Connect the negative battery cable.

Tighten
Tighten the bolt to 15 N·m (11 lb ft).

7. Open the manual shut-off valve.
8. Start the vehicle and use the J 41416 in order to inspect for CNG fuel leaks at each serviced fitting.