Fuel Feed Pipe Replacement - Underbody (Long Wheelbase)

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5606780 Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) Single Use Fasteners and Components Intake Manifold Gasket [8x]

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Relieve the fuel system pressure. Fuel Pressure Relief

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 1

3. Air Cleaner Outlet Duct Bracket Bolt (1) » Remove
4. Remove engine wiring harness from air cleaner outlet duct bracket.

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 2

5. Positive Crankcase Ventilation Fresh Air Tube (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
6. Air Cleaner Outlet Duct Clamp (2) » Loosen [2x]
7. Air Cleaner Outlet Duct (3) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 3

8. Plenum Front Panel Outer Reinforcement (1) » Remove — Plenum Front Panel Outer Reinforcement Removal and Installation

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 4

9. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Disengage — Plastic Collar Quick Connect Fitting Service
10. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Remove and position aside

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 5

11. Engine Wiring Harness Connector (1) @ Throttle Body » Disconnect
12. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Remove [2x]
13. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Disconnect
14. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Disconnect

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 6

15. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 7

16. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [3x]

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 8

17. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Disconnect and reposition — Plastic Collar Quick Connect Fitting Service

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 9

Note

Some components not shown for graphic clarity.

18. Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
19. Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 10

20. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Remove [4x]

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 11

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

21. Remove the intake manifold and intake manifold cover (1) as an assembly.
22. Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 12

23. Intake Manifold Gasket (1) » Remove and DISCARD [8x]

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 13

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 24. Fuel Pump Insulator (1) » Remove 25. Disconnect all wiring harness retainers from the fuel feed and evaporative emission pipe.

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 14

26. Fuel Feed and Return Front Hose Bracket Nut (1) » Remove
27. Fuel Feed Pipe (2) » Disconnect — Metal Collar Quick Connect Fitting Service
28. Evaporative Emission Canister Purge Tube (3) » Disconnect — Plastic Collar Quick Connect Fitting Service
29. Fuel Feed and Evaporative Emission Pipe (4) » Remove
30. Raise and support the vehicle. Lifting and Jacking the Vehicle

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 15

31. Retainer (1) @ Fuel Feed and Return Front Hose Bracket (2) » Remove
32. Fuel Feed and Return Front Pipe (4) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 16

33. Evaporative Emission Canister Hose (1) » Disconnect [2x] — Plastic Collar Quick Connect Fitting Service
34. Evaporative Emission Canister Hose (1) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 17

35. Evaporative Emission Canister Filter Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 18

36. Evaporative Emission Canister Bracket Bolt (1) » Remove
37. Auxiliary Evaporative Emission Canister (2) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 19

38. Evaporative Emission Canister Vent Hose (1) » Disconnect — Plastic Collar Quick Connect Fitting Service
39. Evaporative Emission Pipe (2) » Disconnect — Plastic Collar Quick Connect Fitting Service

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 20

Note

It is not necessary to remove the evaporative emission canister bracket nuts.

40. Evaporative Emission Canister Bracket Nut (1) » Loosen [2x]

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 21

41. Evaporative Emission Canister (1) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 22

42. Fuel Feed and Evaporative Emission and Return Pipe Clip Bracket Bolt (1) » Remove
43. Fuel Feed Pipe (2) » Disconnect — Plastic Collar Quick Connect Fitting Service
44. Retainer (3) » Remove [2x]

Note

Maneuver the fuel feed and return front pipe along side the transmission towards the rear of the vehicle.

45. Fuel Feed and Return Front Pipe (4) » Remove

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 23

46. Fuel Feed Pipe (1) @ Retainer (2) » Disengage [7x]
47. Fuel Feed Pipe (1) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Fuel Feed Pipe Replacement - Underbody (Long Wheelbase) — figure 24

1. Clean all sealing surfaces.

2. Dry the intake manifold with compressed air.

3. Inspect the intake manifold cylinder head deck for warpage.

4. Place a straight edge (1) across the intake manifold cylinder head deck surface.

5. Inspect the intake manifold for the following conditions: 5.1. Inspect for loose threaded inserts or studs. 5.2. Inspect for damaged or broken vacuum fitting. 5.3. Inspect the intake manifold assembly for cracks or other damage. 5.4. Inspect for damaged intake manifold gasket sealing surfaces.

6. Position the straight edge (1) across a minimum of two runner port openings and check for warpage using a feeler gage. Engine Mechanical Specifications

7. Inspect the ventilation system passages for restrictions. Installation Procedure

8. Fuel Feed Pipe (1) » Install

9. Fuel Feed Pipe (1) @ Retainer (2) » Engage [7x]

10. Fuel Feed and Return Front Pipe (4) » Install

11. Retainer (3) » Install [2x]

12. Fuel Feed Pipe (2) » Connect — Plastic Collar Quick Connect Fitting Service

Caution

Refer to Fastener Caution.

6. Fuel Feed and Evaporative Emission and Return Pipe Clip Bracket Bolt (1) » Install and tighten — Fastener Specifications

7. Evaporative Emission Canister (1) » Install

8. Evaporative Emission Canister Bracket Nut (1) » Tighten [2x] — Fastener Specifications

9. Evaporative Emission Pipe (2) » Connect — Plastic Collar Quick Connect Fitting Service

10. Evaporative Emission Canister Vent Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

11. Auxiliary Evaporative Emission Canister (2) » Install

12. Evaporative Emission Canister Bracket Bolt (1) » Install and tighten — Fastener Specifications

13. Evaporative Emission Canister Filter Hose (1) » Connect — Plastic Collar Quick Connect Fitting Service

14. Evaporative Emission Canister Hose (1) » Install

15. Evaporative Emission Canister Hose (1) » Connect [2x] — Plastic Collar Quick Connect Fitting Service

16. Fuel Feed and Return Front Pipe (4) » Install

17. Retainer (1) @ Fuel Feed and Return Front Hose Bracket (2) » Install

18. Lower the vehicle.

19. Fuel Feed and Evaporative Emission Pipe (4) » Install

20. Evaporative Emission Canister Purge Tube (3) » Connect — Plastic Collar Quick Connect Fitting Service

21. Fuel Feed Pipe (2) » Connect — Metal Collar Quick Connect Fitting Service

22. Fuel Feed and Return Front Hose Bracket Nut (1) » Install and tighten — Fastener Specifications

23. Connect all wiring harness retainers to the fuel feed and evaporative emission pipe.

Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death. 24. Fuel Pump Insulator (1) » Install

25. Intake Manifold Gasket (1) » Install NEW [8x]

26. Clean all sealing surfaces.

27. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 27.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 27.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 27.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 27.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

Note

The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.

28. Position the intake manifold and Intake manifold cover (1) to install harness retainers.

29. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

30. Move the intake manifold and intake manifold cover (2) into place.

Note

Some components not shown for graphic clarity.

31. Intake Manifold Bolt (1) » Hand tighten [10x]

Caution

Refer to Fastener Caution.

32. Intake Manifold Bolt (1) » Tighten in sequence [10x] — Fastener Specifications

33. Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold » Install — Plastic Collar Quick Connect Fitting Service

34. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [3x]

35. Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) » Install [4x]

36. Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve » Connect

37. Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor » Connect

38. Engine Wiring Harness Retainer (2) @ Intake Manifold Cover » Install [2x]

39. Engine Wiring Harness Connector (1) @ Throttle Body » Connect

40. Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve » Install

41. Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve » Engage — Plastic Collar Quick Connect Fitting Service

42. Plenum Front Panel Outer Reinforcement (1) » Install — Plenum Front Panel Outer Reinforcement Removal and Installation

43. Air Cleaner Outlet Duct (3) » Install

44. Air Cleaner Outlet Duct Clamp (2) » Tighten [2x] — Fastener Specifications

45. Positive Crankcase Ventilation Fresh Air Tube (1) » Connect — Plastic Collar Quick Connect Fitting Service

46. Air Cleaner Outlet Duct Bracket Bolt (1) » Install and tighten — Fastener Specifications

47. Install engine wiring harness to air cleaner outlet duct bracket.

48. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

49. Pressurize fuel system and check for leaks.