K 2500 Truck 4WD V8-305 5.0L VIN M SFI (1996)
Diagram
Removal Procedure
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Service and Repair
3. Disconnect the fittings at the engine compartment fuel feed and return pipes.
4. Disconnect the fuel pipe attaching hardware.
5. Disconnect the fuel feed and return pipe nuts at the fuel inlet and fuel outlet assembly.
6. Disconnect the fuel feed and return pipes and O-rings. Discard O-rings.
7. Remove the fuel tank. Refer to Fuel Tank Assembly. See: Fuel Tank/Service and Repair
8. Disconnect the fuel feed and vapor hoses.
9. Remove the hardware retaining section of pipe to be replaced. Note location of attaching hardware for installation.
10. Remove the section of pipe and hoses.
11. Remove rust or burrs from the engine compartment fuel pipes by the following procedure:
11.1.
Use emery cloth in a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface.
11.2.
Using a clean shop towel, wipe off the male tube ends.
11.3.
Inspect all the connectors for dirt and burrs. Clean or replace the components/assemblies as required.
Installation Procedure
WARNING: To Reduce the Risk of Fire and Personal Injury: Before connecting the fitting, always apply a few drops of clean engine oil to the
male pipe end. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the
female connector wall swell and may prevent proper reconnection if not lubricated.
1. Install the new O-rings on the engine fuel feed and return pipes.
2. Connect the fuel feed and return pipes to the fuel injection unit. Finger tighten only.
3. Connect the fuel pipe attaching hardware.
Tighten
-
Fuel pipe attaching nuts to 27 N.m (20 lb. ft.) using a back-up wrench.
4. Position new fuel pipe harness in original location and fuel pipe harness attaching hardware.
5. Remove protective caps from one end of both fuel pipes. Leave caps on other end of pipes to prevent dirt from entering.
6. Apply a few drops of clean engine oil to the male connector tube ends.
7. Connect the quick-connect fittings at the fuel feed and pipe near the in-line filter and at the fuel sender assembly. Refer Fuel hose and Pipes. See:
Fuel Pressure Connection
8. Install the fuel tank and attaching hardware if the tank was removed.
9. Tighten the fuel filler cap.
10. Connect the negative battery cable.
11. Check for fuel leaks.
11.1.
Turn the ignition switch to the ON position for 2 seconds.
11.2.
Turn the ignition switch to the OFF position for 10 seconds.
11.3.
Again, turn the ignition switch to the ON position.
11.4.
Check for fuel leaks.
Fuel Vapor Pipes and Hoses
