Fuel Hose/Pipes Replacement - Chassis (1500 Crew Cab)

FUEL HOSE/PIPES REPLACEMENT - CHASSIS (1500 CREW CAB)

REMOVAL PROCEDURE

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Disconnect the fuel feed line (1) fitting at the engine.
3. Disconnect the EVAP canister purge tube (2) fitting.
4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
5. Raise and support the vehicle. Refer to Vehicle Lifting.




6. Remove the fuel pipe bracket nut.
7. Remove the fuel pipe bracket from the bellhousing stud.
8. Remove the heated oxygen (HO2S) sensor connector from the bracket.




9. Remove the fuel line clip from the bracket on the transmission.
10. Remove the fuel line clip from the bracket on the transfer case, if equipped with 4 wheel drive (4WD).
11. Remove the clip from the bracket on the frame.
12. Remove the transfer case harness from the clip bracket.

IMPORTANT: The area around the electro-hydraulic control unit (EHCU) MUST be free from loose dirt to prevent contamination of disassembled anti-lock brake (ABS) components.




13. Thoroughly wash all contaminants from around the EHCU.

14. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).




15. Disconnect the brake lines from the brake pressure modulator valve (BPMV).
16. Remove the bolts (4) attaching the EHCU bracket to the frame (5).
17. Remove the EHCU (1).




18. Remove the torsion bar bracket, if equipped with 4WD.
19. Remove the EVAP canister.
20. Disconnect the fuel line at the tank.
21. Cap the fuel and EVAP lines in order to avoid possible system contamination.
22. Remove the fuel/EVAP bundle clip nuts.
23. Remove the fuel/EVAP bundle.

INSTALLATION PROCEDURE




1. Install the fuel/EVAP bundle.

NOTE: Refer to Fastener Notice.

2. Install the fuel/EVAP bundle clip nuts.

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

3. Remove the caps from the fuel and EVAP lines.
4. Connect the fuel line at the tank.
5. Install the EVAP canister.
6. Install the torsion bar bracket, if equipped with 4WD.




7. Install the EHCU (1).
8. Install the bolts (4) attaching the EHCU bracket to the frame (5).

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

9. Connect the brake lines to the BPMV.

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




10. Connect the chassis electrical harness connectors to the EBCM.




11. Install the transfer case harness to the clip bracket.
12. Install the clip to the bracket on the frame.
13. Install the fuel line clip to the bracket on the transfer case, if equipped with 4WD.
14. Install the fuel line clip to the bracket on the transmission.




15. Install the HO2S sensor connector to the bracket.
16. Install the fuel pipe bracket to the bellhousing stud.
17. Install the fuel pipe bracket nut.

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

18. Lower the vehicle.




19. Remove the caps from the fuel rail and EVAP lines.
20. Connect the EVAP canister purge tube (2) fitting.
21. Connect the fuel feed line (1) fitting at the engine.
22. Install the fuel fill cap.
23. Connect the negative battery cable.
24. 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.