Fuel Hose/Pipes Replacement - Chassis Cab Chassis
Removal Procedure
- Disconnect the chassis
fuel pipes from the engine fuel pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Remove the retaining nut from the fuel bundle bracket.
- Remove the fuel tank. Refer to
Fuel Tank Replacement
.
- Remove the fuel bundle
clips (2) from the transmission brackets (1).
- Disconnect the chassis harness from the retaining clips.
- Remove the fuel system cooler. Refer to
Fuel Cooler Replacement
.
- Cap off the fuel pipes to prevent contamination.
- Remove the fuel bundle retaining nuts (2) from the chassis (1).
- Disconnect the electronic
brake control module mounting bracket (3) from the frame rail (5).
- Allow the electronic brake control module to remain loose in order
to allow fuel pipe clearance.
- Remove the fuel bundle (3) using the following procedure:
11.1. | Guide the fuel bundle (2) pipes towards the rear of vehicle to
clear the engine. |
11.2. | Lower the fuel bundle while moving it foreword and out. |
Notice: Do not attempt to straighten any kinked nylon fuel lines.
Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.
- If replacing
an individual fuel pipe, remove the pipe from the retaining clips.
Installation Procedure
- If replacing an individual fuel pipe, place the new fuel pipe
in the retaining clips.
- Install the fuel bundle (3) to the chassis (1) using the following procedure:
2.1. | Install the fuel bundle (3) to the chassis by guiding the pipes
towards the rear of vehicle. |
2.2. | Lift the fuel pipes, while guiding the forward portion of the
pipes up towards the engine connections. |
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.
- Attach the fuel
bundle to the chassis.
Tighten
Tighten the fuel bundle retaining nuts (1) to 16 N·m (12 lb ft).
- Remove the fuel caps.
- Install the system cooler. Refer to
Fuel Cooler Replacement
.
- Connect the fuel bundle
clips (2) to the transmission brackets (1).
- Install the fuel tank. Refer to
Fuel Tank Replacement
.
- Install the electronic
brake control module mounting bracket (3) to the frame rail (5).
Tighten
Tighten the EBCM bracket retaining bolts (4) to 25 N·m
(18 lb ft).
- Lower the vehicle.
- Install the fuel bundle
bracket.
Tighten
Tighten the fuel bundle bracket retaining nut to 16 N·m
(12 lb ft).
- Connect the chassis fuel pipes to the engine fuel pipes. Refer
to
Metal Collar Quick Connect Fitting Service
.
- Purge air from the fuel system. Refer to
Fuel Feed Pipe and Return Pipe Purging
.
Fuel Hose/Pipes Replacement - Chassis Cab Chassis Balance
Removal Procedure
- Remove the front fuel
tank (5). Refer to
Fuel Tank Replacement
.
- Remove the auxiliary fuel tank (2). Refer to
Fuel Tank Replacement
.
Notice: Do not attempt to straighten any kinked nylon fuel lines.
Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.
- Remove the
fuel pipes (2) using the following procedure:
• | For the return pipe, remove the fuel pipe from the retaining clips. |
• | For a balance pump fuel line, disconnect the fuel pipe from the
balance pump and the retaining clips. |
Installation Procedure
Notice: Do not attempt to straighten any kinked nylon fuel lines.
Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.
- Install the
fuel pipes (2) using the following procedure:
• | For the return pipe, install the fuel pipe to the retaining clips. |
• | For a balance pump fuel line, connect the fuel pipe to the balance
pump and the retaining clips. |
- Install the auxiliary
fuel tank (2). Refer to
Fuel Tank Replacement
.
- Install the front fuel tank. Refer to
Fuel Tank Replacement
.
Fuel Hose/Pipes Replacement - Chassis Pickup
Tools Required
Removal Procedure
- Disconnect the chassis
fuel pipes from the engine fuel pipes. Refer to
Metal Collar Quick Connect Fitting Service
.
- Remove the retaining nut from the fuel bundle bracket.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the fuel bundle
clips (2) from the transmission brackets (1).
- Disconnect the chassis harness from the retaining clips.
- Remove the fuel system
cooler (1) if necessary. Refer to
Fuel Cooler Replacement
.
- Disconnect the chassis
fuel pipes (1, 2) from the fuel tank fuel pipes.
- Remove the fuel bundle
retaining nuts (1) from the chassis.
- Disconnect the electronic
brake control module mounting bracket (3) from the frame rail (5).
- Allow the electronic brake control module to remain loose in order
to allow fuel pipe clearance.
- Remove the fuel bundle using the following procedure:
11.1. | Guide the fuel bundle (2) pipes towards the rear of vehicle to
clear the engine. |
11.2. | Lower the fuel bundle while moving it foreword and out. |
Installation Procedure
- Install the fuel pipe
bundle using the following procedure:
1.1. | Install the fuel bundle (3) to the chassis by guiding the pipes
towards the rear of vehicle. |
1.2. | Lift the fuel pipes, while guiding the forward portion of the
pipes up towards the engine connections. |
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.
- Attach the fuel
bundle to the chassis.
Tighten
Tighten the fuel bundle retaining nuts (1) to 16 N·m (12 lb ft).
- Install the fuel system
cooler (1). Refer to
Fuel Cooler Replacement
.
- Connect the fuel bundle
clips (2) to the transmission brackets (1).
- Install the electronic
brake control module mounting bracket (3) to the frame rail (5).
Tighten
Tighten the retaining bolts (4) to 25 N·m (18 lb ft).
- Lower the vehicle.
- Install the fuel bundle
bracket.
Tighten
Tighten the bundle bracket retaining nut to 16 N·m (12 lb ft).
- Connect the chassis fuel pipes to the engine fuel pipes. Refer
to
Metal Collar Quick Connect Fitting Service
.
- Purge air from the fuel system. Refer to
Fuel Feed Pipe and Return Pipe Purging
.