Fuel Hose/Pipes Replacement - Chassis (Extended Cab With 8 Ft Bed

Fuel Hose/Pipes Replacement - Chassis (Extended Cab - w/8 Ft Bed)

Removal Procedure

Important: 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 (With CH 48027) Fuel Pressure Relief (Without CH 48027).
2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line.
3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail.
4. Cap the fuel rail and EVAP pipes.
5. Raise and support the vehicle. Refer to Vehicle Lifting.
6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.




7. Remove the fuel pipe bracket nut from the bellhousing stud.




8. Remove the fuel line clip (1) 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 EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way.
11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.




12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line.
14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
15. Remove the fuel line bracket bolt (2).
16. Remove the fuel/EVAP line clip nut (1).
17. Remove the fuel/EVAP line clips from the frame and crossmember.
18. Remove the fuel/EVAP line assembly from the vehicle.




19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service.
20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line.
21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination.
22. Remove the fuel line bracket bolt (1).
23. Remove the fuel/EVAP line clip nut (2).
24. Remove the fuel/EVAP line clips from the frame and crossmember.
25. Remove the fuel/EVAP line assembly from the vehicle.

Installation Procedure




1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
2. Install the fuel/EVAP line bracket locator tab to the frame.
3. Install the fuel/EVAP line clips to the frame and crossmember.

Notice: Refer to Fastener Notice.

4. Install the fuel/EVAP line bracket bolt (1).

Tighten the bolt to 9 N.m (80 lb in).

5. Install the fuel/EVAP line clip nut (2).

Tighten the nut to 20 N.m (15 lb ft).

6. Remove the caps from the fuel and EVAP lines.
7. Connect the fuel tank EVAP line quick connect fitting to the chassis line.
8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line.




9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle.
10. Install the fuel/EVAP line bracket locator tab to the frame.
11. Install the fuel/EVAP line clips to the frame and crossmember.
12. Install the fuel/EVAP line bracket bolt (2).

Tighten the bolt to 9 N.m (80 lb in).

13. Install the fuel/EVAP line clip nut (1).

Tighten the nut to 20 N.m (15 lb ft).

14. Remove the caps from the fuel and EVAP lines.
15. Connect the fuel tank EVAP line quick connect fitting to the chassis line.
16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line.




17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line.
18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line.




19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
20. Install the fuel line clip (1) to the bracket on the automatic transmission.




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

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

22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement.
23. Lower the vehicle.




24. Remove the caps from the fuel rail and EVAP line.
25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line.
26. Connect the fuel feed line (1) quick connect fitting to the fuel rail.
27. Install the fuel fill cap.
28. Connect the negative battery cable.
29. 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.