Fuel Hose/Pipes Replacement - Chassis (Pickup)

FUEL HOSE/PIPES REPLACEMENT - CHASSIS (PICKUP)

REMOVAL PROCEDURE

IMPORTANT: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines 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) at the engine.
3. Disconnect the EVAP canister purge tube line (2).
4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
5. If equipped with a manual transmission, raise and suitably support the vehicle. Refer to Vehicle Lifting.
6. If equipped with an automatic transmission, remove the transmission.
7. Remove the fuel pipe bracket nut.
8. Remove the fuel pipe bracket from the bellhousing stud.
9. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
10. Remove the fuel line clip from the bracket on the transmission.
11. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
12. Remove the clip from the bracket on the frame.
13. 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 antilock brake (ABS) components.




14. Thoroughly wash all contaminants from around the EHCU.

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

IMPORTANT: Make sure the brake lines are tagged and kept in order for proper reassembly.




16. Disconnect the brake lines from the brake pressure modulator valve (BPMV).

17. Remove the bolts (4) attaching the EHCU bracket to the frame (5).
18. Remove the EHCU (1).




19. If equipped with 4WD, remove the torsion bar bracket.
20. Disconnect the fuel and EVAP lines at the fuel tank.
21. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.




22. Remove the fuel and EVAP bundle clip nuts.
23. Remove the fuel and EVAP bundle.

INSTALLATION PROCEDURE




1. Install the fuel and EVAP bundle.

NOTE: Refer to Fastener Notice.

2. Install the fuel and EVAP bundle clip nuts.

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




3. Remove the caps from the fuel and EVAP lines at the fuel tank.
4. Connect the fuel and EVAP quick connect fittings.
5. If equipped with 4WD, install the torsion bar bracket.




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

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




8. Connect the brake lines to the BPMV.

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

9. Connect the chassis electrical harness connectors to the EBCM.
10. Install the transfer case harness to the clip bracket.
11. Install the clip to the bracket on the frame.
12. If removed, install the automatic transmission.
13. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
14. Install the fuel line clips to the brackets 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 line.
20. Connect the fuel feed line (1) at the engine.
21. Connect the EVAP canister purge tube line (2).
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.