Fuel Hose/Pipes Replacement - Chassis 1500 Series

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 fuel feed pipe (1) at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
3. Disconnect the evaporative emission (EVAP) canister purge pipe (2).
4. Cap the fuel rail and EVAP pipes.
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Unbolt and reposition the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.



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



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



11. Remove the fuel line bracket bolt.



12. Disconnect the fuel feed and EVAP lines from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
13. Cap the fuel and EVAP lines at the fuel tank.



14. Remove the fuel and EVAP line clips from the frame and brace.
15. Remove the fuel/EVAP line bundle.

1. Install the fuel/EVAP line bundle.
2. Install the fuel and EVAP line clips to the frame and brace.



3. Remove the caps from the fuel and EVAP lines at the fuel tank.
4. Connect the fuel feed and EVAP lines to the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .

Notice: Refer to Fastener Notice in the Preface section.




5. Install the fuel line bracket bolt.

Tighten
Tighten the bolt to 12 N·m (106 lb in).




6. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
7. Install the fuel line clip to the bracket on the automatic transmission.



8. Install the fuel pipe bracket to the bellhousing stud.
9. Install the fuel pipe bracket nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).




10. Reposition and install the front propeller shaft bolts. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
11. Lower the vehicle.
12. Remove the caps from the fuel rail and EVAP line.
13. Connect the EVAP canister purge line (2).
14. Connect the fuel feed line (1) at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
15. Install the fuel fill cap.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
17. Use the following procedure in order to inspect for leaks:

17.1.

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

17.2.

Turn the ignition OFF for 10 seconds.

17.3.

Turn the ignition ON, with the engine OFF.

17.4.

Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis 2500 Series - Front

Important: Clean all fuel and evaporative emission (EVAP) line 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 Fuel Pressure Relief .
2. Disconnect the fuel feed pipe (1) at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
3. Disconnect the evaporative emission (EVAP) canister purge pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
4. Cap the fuel rail and EVAP pipes.
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



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



8. Remove the fuel line clip 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 front fuel tank. Refer to Fuel Tank Replacement .



11. Remove the fuel line bracket nuts.
12. Remove the fuel/EVAP line bundle.

Notice: Refer to Fastener Notice in the Preface section.




1. Install the fuel/EVAP line bundle.
2. Install the fuel line bracket nuts.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

3. Install the front fuel tank. Refer to Fuel Tank Replacement .



4. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
5. Install the fuel line clip to the bracket on the automatic transmission.



6. Install the fuel pipe bracket to the bellhousing stud.
7. Install the fuel pipe bracket nut.

Tighten
Tighten the nut to 10 N·m (89 lb in).

8. Lower the vehicle.



9. Remove the caps from the fuel rail and EVAP pipe.
10. Connect the EVAP canister purge pipe (2). Refer to Plastic Collar Quick Connect Fitting Service .
11. Connect the fuel feed line (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
12. Install the fuel fill cap.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Use the following procedure in order to inspect for leaks:

14.1.

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

14.2.

Turn the ignition OFF for 10 seconds.

14.3.

Turn the ignition ON, with the engine OFF.

14.4.

Inspect for fuel leaks.

Fuel Hose/Pipes Replacement - Chassis 1500 Series - 5.3L (L59) Engine

Important: Clean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination.

1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
2. Disconnect the fuel feed pipe (1) at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
3. Disconnect the evaporative emission (EVAP) canister purge pipe (2).
4. Cap the fuel rail and EVAP pipes.
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Unbolt and reposition the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.



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



9. Remove the fuel line clip from the bracket on the automatic transmission.
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. Refer to Evaporative Emission Canister Replacement .
12. Remove the fuel filter bracket bolt.



13. Disconnect the fuel feed and EVAP pipes from the fuel tank lines. Refer to Plastic Collar Quick Connect Fitting Service .
14. Cap the fuel and EVAP pipes at the fuel tank.



15. Remove the fuel and EVAP line clips from the frame and brace.
16. Remove the fuel/EVAP line bundle.

1. Install the fuel/EVAP line bundle.
2. Install the fuel and EVAP line clips to the frame and brace.



3. Remove the caps from the fuel pipes at the fuel tank.
4. Connect the fuel feed and EVAP pipes to the fuel tank pipes. Refer to Plastic Collar Quick Connect Fitting Service .



5. Insert the integral locator tab into the hole in the frame.

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.

6. Install the fuel pipe/hose bracket bolt.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

7. Install the EVAP canister. Refer to Evaporative Emission Canister Replacement .



8. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
9. Install the fuel hose/pipe clip to the bracket on the automatic transmission.



10. Install the fuel pipe bracket to the bellhousing stud.
11. Install the fuel pipe bracket nut (2).

Tighten
Tighten the nut to 10 N·m (89 lb in).

12. Reposition and install the front propeller shaft bolts. Refer to Front Propeller Shaft Replacement in Propeller Shaft.



13. Lower the vehicle.
14. Remove the caps from the fuel rail and EVAP pipes.
15. Connect the EVAP canister purge line (2).
16. Connect the fuel feed line (1) at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
19. Use the following procedure in order to inspect for leaks:

19.1.

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

19.2.

Turn the ignition OFF for 10 seconds.

19.3.

Turn the ignition ON, with the engine OFF.

19.4.

Inspect for fuel leaks.