Fuel Hose/Pipes Replacement - Chassis Regular Cab

Important: 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 quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect the fuel feed line (1) quick connect fitting 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, if required. Refer to Front Propeller Shaft Replacement .



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



8. Remove the fuel line clip (1) from the bracket on the automatic transmission.
9. Unclip the oxygen sensor harness connector from the bracket.
10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.



11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.



13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
16. Unclip the inline harness connector from the bracket.
17. Remove the fuel line bracket bolt (1).
18. Remove the fuel/EVAP line clip nut (2).
19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines.
20. Unclip the line assembly from the frame.
21. Remove the fuel/EVAP line clips from the frame and crossmember.
22. Remove the fuel/EVAP line assembly from the vehicle.

1. Position and install the fuel/EVAP line assembly to the vehicle.
2. Clip the line assembly to the frame.
3. Tighten the BPMV bolts.
4. Install the fuel/EVAP line bracket locator tab to the frame.
5. Install the fuel/EVAP line clips to the frame and crossmember.
6. Clip the inline electrical connector to the bracket.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the fuel/EVAP line bracket bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

8. Install the fuel/EVAP line clip nut (2).

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

9. Remove the caps from the fuel and EVAP lines.
10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .



12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line.



14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
15. Install the fuel line clip (1) to the bracket on the automatic transmission.



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

Tighten
Tighten the nut to 25 N·m (18 lb ft).

17. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .
18. Lower the vehicle.



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

24.1.

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

24.2.

Turn the ignition OFF for 10 seconds.

24.3.

Turn the ignition ON, with the engine OFF.

24.4.

Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Extended Cab

Important: 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 quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect the fuel feed line (1) quick connect fitting 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, if required. Refer to Front Propeller Shaft Replacement .



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



8. Remove the fuel line clip (1) 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 EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line.



12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. 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 line bracket bolt (1).
16. Remove the fuel/EVAP line clip nut (2).
17. Remove the fuel/EVAP line clips from the frame and crossmember.
18. Remove the fuel/EVAP line assembly from the vehicle.

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

Notice: Refer to Fastener Notice in the Preface section.

4. Install the fuel/EVAP line bracket bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

5. Install the fuel/EVAP line clip nut (2).

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

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



9. Unscure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line.



11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
12. Install the fuel line clip (1) to the bracket on the automatic transmission.



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

Tighten
Tighten the nut to 25 N·m (18 lb ft).

14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .
15. Lower the vehicle.



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

21.1.

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

21.2.

Turn the ignition OFF for 10 seconds.

21.3.

Turn the ignition ON, with the engine OFF.

21.4.

Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Extended Cab - w/8 Ft Bed

Important: 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 quick connect fitting (2) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect the fuel feed line (1) quick connect fitting 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, if required. Refer to Front Propeller Shaft Replacement .



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



8. Remove the fuel line clip (1) 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 EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.



12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
13. Disconnect the fuel tank EVAP line quick connect fitting 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 line bracket bolt (2).
16. Remove the fuel/EVAP line clip nut (1).
17. Remove the fuel/EVAP line clips from the frame and crossmember.
18. Remove the fuel/EVAP line assembly from the vehicle.



19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
22. Remove the fuel line bracket bolt (1).
23. Remove the fuel/EVAP line clip nut (2).
24. Remove the fuel/EVAP line clips from the frame and crossmember.
25. Remove the fuel/EVAP line assembly from the vehicle.

1. If equipped with 4WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle.
2. Install the fuel/EVAP line bracket locator tab to the frame.
3. Install the fuel/EVAP line clips to the frame and crossmember.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the fuel/EVAP line bracket bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

5. Install the fuel/EVAP line clip nut (2).

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

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



9. If equipped with 2WD perfrom the following steps, position and install the fuel/EVAP line assembly to the vehicle.
10. Install the fuel/EVAP line bracket locator tab to the frame.
11. Install the fuel/EVAP line clips to the frame and crossmember.
12. Install the fuel/EVAP line bracket bolt (2).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

13. Install the fuel/EVAP line clip nut (1).

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

14. Remove the caps from the fuel and EVAP lines.
15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .
16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service .



17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.



19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
20. Install the fuel line clip (1) to the bracket on the automatic transmission.



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

Tighten
Tighten the nut to 25 N·m (18 lb ft).

22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement .
23. Lower the vehicle.



24. Remove the caps from the fuel rail and EVAP line.
25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service .
26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
27. Install the fuel fill cap.
28. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
29. Use the following procedure in order to inspect for leaks:

29.1.

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

29.2.

Turn the ignition OFF for 10 seconds.

29.3.

Turn the ignition ON, with the engine OFF.

29.4.

Inspect for fuel leaks.