Fuel Hose/Pipes Assembly Replacement 2500 Series - Front Tank

Important: Clean the fuel feed pipe connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect and remove the fuel feed line (4) from the module and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect and remove the rear fuel feed line (2) from the module and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel feed and EVAP lines.
2. Install and connect the rear fuel feed line (2) to the module and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Install and connect the fuel feed (4) line to the module and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Hose/Pipes Assembly Replacement 2500 Series - Intermediate

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. Remove the spare tire stowage lock cylinder.



3. Remove the spare tire.
4. Drain the rear fuel tank. Refer to Fuel Tank Draining .
5. Remove the rear exhaust insulator.



6. Remove the spare tire hoist crossmember bolts and crossmember.



7. Disconnect the EVAP canister quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .



8. Disconnect the fuel and EVAP intermediate lines from the front tank. Refer to Plastic Collar Quick Connect Fitting Service .



9. Disconnect the fuel pressure sensor electrical connector (1).



10. Support the fuel tank with a suitable jack.

Notice: Refer to Damage to Fuel Tank Straps Notice in the Preface section.

11. Remove the fuel tank strap bolts.
12. Remove the fuel tank straps.
13. With the aid of an assistant, lower the rear tank until the intermediate line connections can be reached.



14. Disconnect the fuel and EVAP intermediate lines from the rear tank. Refer to Plastic Collar Quick Connect Fitting Service .
15. Remove the fuel and EVAP intermediate lines.
16. Cap the fuel and EVAP lines in order to prevent possible EVAP/fuel system contamination.

1. Remove the caps from the fuel and EVAP lines.
2. Install the fuel and EVAP intermediate lines.
3. Connect the fuel and EVAP intermediate lines to the rear tank. Refer to Plastic Collar Quick Connect Fitting Service .



4. With the aid of an assistant, completely raise the rear tank.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the fuel tank straps.
6. Install the fuel tank strap bolts.

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

7. Remove the adjustable jack from under the fuel tank.



8. Connect the fuel pressure sensor electrical connector (1).



9. Connect the fuel and EVAP intermediate lines to the front tank. Refer to Plastic Collar Quick Connect Fitting Service .



10. Connect the EVAP canister quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .



11. Install the spare tire hoist crossmember and bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




12. Install the rear exhaust insulator.
13. Install the spare tire.



14. Install the spare tire stowage lock cylinder.



15. Install the fuel tank filler housing.
16. Install the fuel tank filler housing to fuel tank fill pipe bolts.

Tighten
Tighten the bolts to 2.3 N·m (20 lb in).




17. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (20 lb in).

18. Refill the fuel tank.
19. Install the fuel fill cap.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
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 Assembly Replacement 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. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the fuel feed pipe (4) and return pipe (5) from the sending unit (2). Refer to Plastic Collar Quick Connect Fitting Service .
3. Disconnect the fuel feed pipe (4) and return pipe (5) from the fuel tank clips (6).
4. Cap the fuel pipes in order to prevent possible fuel system contamination.

1. Remove the caps from the fuel pipes.
2. Connect the fuel feed pipe (4) and return pipe (5) to the fuel tank clips (6).
3. Connect the fuel feed pipe (4) and return pipe (5) to the sending unit (2). Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Hose/Pipes Assembly Replacement 1500 Series

Important: Clean the fuel feed pipe connection and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination.

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.

1. Remove the caps from the fuel feed and EVAP lines.
2. Install and connect the fuel feed (1) line to the sending unit and retaining clips. Refer to Plastic Collar Quick Connect Fitting Service .
3. Install the fuel tank. Refer to Fuel Tank Replacement .