Fuel Line Replacement - Chassis (2500 Series)

Fuel Line Replacement - Chassis (2500 Series)

Removal Procedure

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

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

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

4. Cap the fuel rail and EVAP line in order to prevent fuel/EVAP system contamination.

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





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 fuel line bracket nuts.

11. Remove the fuel/EVAP line bundle.

Installation Procedure





1. Install the fuel/EVAP line bundle.

Caution:
Refer to Fastener Caution Fastener Caution.

2. Install the fuel line bracket nuts.

Tighten the bolt to 18 Nm (13 lb ft).





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

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





5. Install the fuel pipe bracket to the bellhousing stud.

6. Install the fuel pipe bracket nut.

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

7. Lower the vehicle.





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

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

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

11. Install the fuel fill cap.

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

13. 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.

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