Fuel Cooler Replacement Pickup

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Relieve the fuel pressure.
3. Disconnect the fuel pipes from the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
4. Remove the fuel cooler bolts (4, 6).
5. Remove the fuel cooler (1).
6. Remove the fuel cooler support bracket bolt (2, 5), and bracket (3) from the fuel cooler (1), if necessary.

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.

1. Install the fuel cooler support bracket (3), and bolts (2, 5) to the fuel cooler (1), if necessary.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

2. Install the fuel cooler (1) to the chassis and crossover.
3. Install the fuel cooler bolts (4, 6).

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

4. Connect the fuel pipes to the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
5. Lower the vehicle.
6. Purge the air from the fuel system.
7. Start the engine and inspect for fuel leaks.

Fuel Cooler Replacement Cab/Chassis

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Relieve the fuel pressure.
3. Disconnect the fuel pipes from the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
4. Remove the fuel cooler nuts (2).
5. Remove the fuel cooler (1).

1. Install the fuel cooler (1).

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 fuel cooler nuts (2).

Tighten
Tighten the nuts to 40 N·m (30 lb ft).

3. Connect the fuel pipes to the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
4. Lower the vehicle.
5. Purge the air from the fuel system.
6. Start the engine and inspect for fuel leaks.