Fuel Line Replacement - Chassis (1500 Series)

Fuel Line Replacement - Chassis (1500 Series)

Removal Procedure

Note:
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 (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027).

2. Disconnect the engine evaporative emission (EVAP) line (1) quick connect fitting from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

3. Disconnect the fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

4. Cap the fuel rail and EVAP pipes.

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

6. Unbolt and reposition the front propeller shaft. Refer to Front Propeller Shaft Replacement .





7. Disconnect the chassis wiring harness electrical connector (1) from the fuel pressure sensor.





8. Remove the fuel pipe bracket nut 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 (3).

12. Disconnect the chassis EVAP line quick connect fitting (4) from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

13. Disconnect the fuel tank fuel feed line quick connect fitting (5) from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.

15. Remove the fuel/EVAP line clips from the frame and crossmember.

16. Remove the fuel line bracket locator tab from the frame.

17. Remove the fuel/EVAP lines from the vehicle.

Installation Procedure





1. Install the fuel/EVAP lines to the vehicle.

2. Install the fuel line bracket locator tab to the frame.

3. Install the fuel/EVAP line clips to the frame and crossmember.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the fuel line bracket bolt (3).

Tighten the bolt to 12 Nm (106 lb in).

5. Remove the caps from the fuel and EVAP lines.

6. Connect the chassis EVAP line quick connect fitting (4) to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

7. Connect the fuel tank fuel feed line quick connect fitting (5) to the chassis line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





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

9. Install the fuel line clip to the bracket on the automatic transmission.





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

Tighten the nut to 20 Nm (15 lb ft).

11. Position and install the front propeller shaft. Refer to Front Propeller Shaft Replacement .





12. Connect the chassis wiring harness electrical connector (1) to the fuel pressure sensor.

13. Lower the vehicle.





14. Remove the caps from the fuel rail and EVAP line.

15. Connect the engine EVAP line (1) quick connect fitting to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.

16. Connect the fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

17. Install the fuel fill cap.

18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

19. Use the following procedure in order to inspect for leaks:

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

2. Turn the ignition OFF for 10 seconds.

3. Turn the ignition ON, with the engine OFF.

4. Inspect for fuel leaks.

20. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement Upper Intake Manifold Sight Shield Replacement.