Fuel Hose/Pipes Replacement - Chassis Pickup

1. Disconnect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service.
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .



5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .



8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .



9. Remove the fuel bundle nuts from the chassis.



10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure:

12.1.

Guide the fuel bundle pipes towards the rear of the vehicle to clear the engine.

12.2.

Lower the fuel bundle while moving it forward and out.

1. Install the fuel pipe bundle using the following procedure:

1.1.	Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle.

Notice: Refer to Fastener Notice in the Preface section.

1.2.	Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections.

2. Install the fuel bundle nuts to the chassis.

Tighten
Tighten the nuts to 16 N·m (12 lb ft).




3. Connect the fuel feed and return lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .



5. Connect the fuel bundle clips (2) to the transmission brackets (1).



6. Tighten the EBCM bracket bolts (4).

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

7. Lower the vehicle.



8. Install the fuel line bracket to the stud.
9. Install the fuel line bracket nut.

Tighten
Tighten the nut to 16 N·m (12 lb ft).

10. Connect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service .
11. Prime the fuel system. Refer to Fuel System Priming .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Cab/Chassis

1. Disconnect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service .
2. Remove the fuel line bracket nut.
3. Remove the fuel line bracket from the stud.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .



5. Remove the fuel bundle clips (2) from the transmission brackets (1).
6. Disconnect the chassis harness from the retaining clips.
7. Remove the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement .



8. Disconnect the fuel feed and return lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .



9. Remove the fuel bundle nuts from the chassis.



10. Loosen the electronic brake control module (EBCM) bracket bolts (4).
11. Allow the EBCM to remain loose in order to allow fuel pipe clearance.
12. Remove the fuel bundle using the following procedure:

12.1.

Guide the fuel bundle pipes towards the rear of vehicle to clear the engine.

12.2.

Lower the fuel bundle while moving it foreword and out.

1. Install the fuel pipe bundle using the following procedure:

1.1.	Install the fuel bundle to the chassis by guiding the pipes towards the rear of vehicle.

Notice: Refer to Fastener Notice in the Preface section.

1.2.	Lift the fuel pipes, while guiding the forward portion of the pipes up towards the engine connections.

2. Install the fuel bundle nuts to the chassis.

Tighten
Tighten the nuts to 16 N·m (12 lb ft).




3. Connect the fuel feed and return lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel system cooler, if necessary. Refer to Fuel Cooler Replacement.



5. Connect the fuel bundle clips (2) to the transmission brackets (1).



6. Tighten the EBCM bracket bolts (4).

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

7. Lower the vehicle.



8. Install the fuel line bracket to the stud.
9. Install the fuel line bracket nut.

Tighten
Tighten the nut to 16 N·m (12 lb ft).

10. Connect the fuel feed and return lines. Refer to Metal Collar Quick Connect Fitting Service .
11. Prime the fuel system. Refer to Fuel System Priming .
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis Cab/Chassis w/Balance Pump

1. Remove the front and auxiliary fuel tanks. Refer to Fuel Tank Replacement.
2. Disconnect the pressure balance pump electrical connector.



3. Remove the fuel bundle nuts.
4. Remove the fuel bundle.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the fuel bundle.
2. Install the fuel bundle nuts.

Tighten
Tighten the nuts to 16 N·m (12 lb ft).




3. Connect the pressure balance pump electrical connector .
4. Install the front and auxiliary fuel tanks. Refer to Fuel Tank Replacement .