Home ReviewsRefund
Home/GMC/Sierra 3500/GMC Sierra 3500 (2002-2006)/Repair manual/Testing & Diagnostics/Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction): Remova…
Contents Wiring diagrams Section: Testing & Diagnostics All sections

Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction): Removal & Installation GMC Sierra 3500

Testing & Diagnostics 2 illustrations ~19193 words

Powertrain Control Module (PCM) Replacement

Service of the powertrain control module (PCM) should consist of either replacement of the PCM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the PCM to be replaced, the replacement PCM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty PCM and install the new service PCM.

Removal Procedure

IMPORTANTTo prevent internal PCM damage, the ignition switch must be OFF when disconnecting or connecting power to the PCM. Remove any debris from around the PCM connector surfaces before servicing the PCM. Inspect the PCM module connector gaskets when diagnosing or replacing the PCM. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the PCM. The replacement PCM must be programmed.
  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  3. If equipped with regular production option (RPO) NYS, remove the harness ground clip from the PCM cover.
  4. Release the PCM cover mounting tabs.
  5. Release the PCM cover from the mounting bracket.
  6. Remove the PCM cover.
  7. Loosen the PCM electrical connector bolts (2). NOTE: Refer to PCM and ESD Notice in Cautions and Notices. NOTE: In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector.
  8. Disconnect the PCM electrical connectors.
  9. Release the spring latch from the PCM.
  10. Release the PCM mounting tabs from the PCM.
  11. Remove the PCM.

Installation Procedure

  1. Install the PCM. Ensure that the mounting tabs are engaged.
  2. Secure the spring latch to the PCM.
  3. Connect the PCM electrical connectors. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Tighten the PCM electrical connector bolts (2). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  5. Install the PCM cover.
  6. If equipped with RPO NYS, install the harness ground clip to the PCM cover.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  8. If a NEW PCM was installed, program the PCM. Refer to «Service Programming System (SPS)»(ref-184120-S18443623862005082200000) in Programming.
  9. Perform the crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184136-S28806049692005082200000) .
  1. Disconnect the instrument panel (I/P) harness electrical connector (2).
  2. Release the red connector position assurance (CPA) retainer.
  3. Disconnect the engine wiring harness electrical connector (1).
  4. Remove the throttle actuator control (TAC) module nuts.
  5. Remove the TAC module.
  1. Install the TAC module. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the TAC module nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  3. Connect the engine wiring harness electrical connector (1).
  4. Install the red CPA retainer.
  5. Connect the I/P harness electrical connector (2).

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Drain the cooling system to a level below the engine cooling temperature (ECT) sensor. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Disconnect the ECT sensor electrical connector (5).
  3. Remove the ECT sensor.

Note. Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Note. Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. If installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  3. Connect the ECT sensor electrical connector (5).
  4. Refill the cooling. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
IMPORTANTUse care when handling the mass air flow/intake air temperature (MAF/IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  2. Pull out the gray connector position assurance (CPA) retainer.
  3. Push down on the black clip in order to disconnect the MAF/IAT sensor electrical connector (4).
  4. Loosen the MAF/IAT clamp.
  5. Remove the MAF/IAT sensor from the air cleaner assembly.
IMPORTANTThe embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine.
  1. Locate the air flow direction arrow (2) on the MAF/IAT sensor.
  2. Install the MAF/IAT sensor to the air cleaner assembly. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Tighten the MAF/IAT clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
  4. Connect the MAF/IAT sensor electrical connector (4).
  5. Push in the gray CPA retainer.
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  2. Disconnect the manifold absolute pressure (MAP) sensor electrical connector (1).
  3. Remove the MAP sensor (1).
IMPORTANTLightly coat the MAP sensor seal with clean engine oil before installing the sensor.
  1. Install the MAP sensor (1).
  2. Connect the MAP sensor electrical connector (1).
  3. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. If necessary, unbolt the front propeller shaft from the front differential. Refer to «Propeller Shaft Replacement - Front»(ref-184221-S09162167182005082200000) in Propeller Shaft.
  3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
  4. Remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip.
  5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (1).
  6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (1).
  7. Remove the HO2S.
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. If equipped with a 6.0L engine, connect the HO2S electrical connector (1).
  4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (1).
  5. Install the HO2S electrical connector to the fuel line clip.
  6. Disconnect the CPA retainer.
  7. If necessary, bolt the front propeller shaft to the front differential. Refer to «Propeller Shaft Replacement - Front»(ref-184221-S09162167182005082200000) in Propeller Shaft.
  8. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. If equipped, disconnect the fuel composition sensor electrical connector.
  3. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
  4. If equipped with a fuel composition sensor, remove the heated oxygen sensor (HO2S) electrical connector from the fuel line clip.
  5. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector (2).
  6. If equipped with a 6.0L engine, disconnect the HO2S electrical connector (2).
  7. Remove the HO2S.
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. If equipped with a 6.0L engine, connect the HO2S electrical connector (2).
  4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector (2).
  5. If equipped with a fuel composition sensor, install the HO2S electrical connector to the fuel line clip.
  6. Disconnect the CPA retainer.
  7. If equipped, connect the fuel composition sensor electrical connector.
  8. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the connector position assurance (CPA) retainer.
  3. Remove the heated oxygen sensor (HO2S) from the clips NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
  4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector.
  5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector.
  6. Remove the HO2S.
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. If equipped with a 6.0L engine, connect the HO2S electrical connector.
  4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector.
  5. Install the HO2S to the clips
  6. Disconnect the CPA retainer.
  7. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the connector position assurance (CPA) retainer. NOTE: Refer to Heated Oxygen and Oxygen Sensor Notice in Cautions and Notices.
  3. Remove the heated oxygen sensor (HO2S) connector clip from the frame.
  4. If equipped with a 4.8L or 5.3L engine, disconnect the HO2S electrical connector.
  5. If equipped with a 6.0L engine, disconnect the HO2S electrical connector.
  6. Remove the HO2S.
IMPORTANTA special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
  1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
  3. If equipped with a 6.0L engine, connect the HO2S electrical connector.
  4. If equipped with a 4.8L or 5.3L engine, connect the HO2S electrical connector.
  5. Install the HO2S connector clip to the frame.
  6. Disconnect the CPA retainer.
  7. Lower the vehicle.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  3. Disconnect the fuel composition sensor electrical connector.
  4. Remove the fuel line retainers (1).
  5. Disconnect the fuel pipes from the fuel composition sensor. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  6. Remove the fuel composition sensor nuts.
  7. Remove the fuel composition sensor.
  8. If required, remove the fuel composition sensor bolts and remove the sensor from the bracket.
  1. If required, install the fuel composition sensor to the bracket and install the bolts. Tighten: Tighten bolts to 10 N.m (89 lb in).
  2. Install the fuel composition sensor.
  3. Install the fuel composition sensor nuts. Tighten: Tighten nuts to 17 N.m (13 lb ft).
  4. Connect the fuel pipes to the fuel composition sensor. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Install the fuel line retainers (1).
  6. Connect the fuel composition sensor electrical connector.
  7. Lower the vehicle.
  8. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

  1. Remove the connector position assurance (CPA) retainer.
  2. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  3. Reposition the carpet to access the lower nut.
  4. Remove the accelerator pedal nuts.
  5. Remove the accelerator pedal assembly.
  1. Install the accelerator pedal assembly. NOTE: Refer to the Fastener Notice in Cautions and Notices.
  2. Install the accelerator pedal nuts. Tighten: Tighten the nuts to 20 N.m (15 lb ft).
  3. Connect the APP sensor electrical connector.
  4. Reposition the carpet.
  5. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  6. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  7. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
  8. Inspect the carpet fit under the accelerator pedal.

Note. Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type.

IMPORTANTDO NOT for any reason, insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate, as the wedge inside the throttle body could be damaged. An 8-digit part identification number is stamped on the throttle body casting. Refer to this number if servicing, or part replacement is required.
  1. Partially drain the cooling system in order to allow the hose at the throttle body to be removed. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  3. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  4. Disconnect the throttle actuator motor electrical connector (2).
  5. Reposition the coolant air bleed hose clamp at the throttle body.
  6. Remove the coolant air bleed hose from the throttle body.
  7. Remove the throttle body nuts.
  8. Remove the throttle body.
  9. Remove and discard the throttle body gasket.
  1. Install the NEW throttle body gasket.
  2. Install the throttle body. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the throttle body nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  4. Install the coolant air bleed hose to the throttle body.
  5. Position the coolant air bleed hose clamp at the throttle body.
  6. Connect the throttle actuator motor electrical connector (2).
  7. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  8. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  9. Refill the cooling system. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
  10. Connect a scan tool in order to test for proper throttle-opening and throttle-closing range.
  11. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT).
  12. Verify that the vehicle meets the following conditions: The vehicle is not in a reduced engine power mode. The ignition is ON. The engine is OFF.
  13. Start the engine.
  14. Inspect for coolant leaks.

Tools Required

J 34730-1A Fuel Pressure Gage

CAUTIONRefer to Gasoline/Gasoline Vapors Caution in Cautions and Notices.
CAUTIONRefer to Fuel Gage Leak Caution in Cautions and Notices.
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  2. Remove the fuel rail pressure fitting cap.
  3. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage.
  4. Install the bleed hose on J 34730-1A into an approved container.
  1. Remove the bleed hose on the J 34730-1A from the approved container.
  2. Remove the shop towel from around the fitting and discard into an approved container.
  3. Disconnect the J 34730-1A from the fuel pressure valve.
  4. Install the fuel rail pressure fitting cap.
  5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184137-S42170646662005082200000) .
  2. Remove the retainer from the fuel feed line to engine quick-connect fitting.
  3. If equipped with the 5.3L (L59) engine, remove the retainers from the fuel feed and return line to engine quick-connect fittings.
  4. Using compressed air, blow any dirt or debris from around the fitting.
  5. Using the correct tool from J 41769 , insert the tool into the female connector, then push inward in order to release the quick connect locking tabs.
  6. If the vehicle is a cab/chassis, it may be necessary to use J 43178 in order to release the quick connect locking tabs.
  7. Pull the fuel line connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.
  8. Use a clean shop towel in order to wipe off the male connection end.
  9. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the fittings together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
  4. If equipped with the 5.3L (L59) engine, install the retainers to the fuel feed and return line to engine quick-connect fittings.
  5. Install the retainer to the fuel feed line quick-connect fitting.
  6. Install the fuel fill cap.
  7. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
IMPORTANTThere are several types of plastic fuel and evaporative emission (EVAP) quick connect fittings used on this vehicle. The following instructions apply to all types of plastic quick connect fittings except where indicated.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Using compressed air, blow any dirt or debris from around the quick connect fitting.
  3. Squeeze the plastic quick connect fitting release tabs together to disengage the quick connect fitting. (This step applies to Bartholomew style fittings ONLY)
  4. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
  5. Squeeze where indicated by the arrows on both sides of the plastic ring to disengage the quick connect fitting.
  6. Pull the quick connect fitting connection apart.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs to snap into place.
  3. Once installed, pull on both sides of the quick-connect fittings in order to make sure the connection is secure.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information
  3. Remove the fuel composition sensor bracket nuts.
  4. Reposition the fuel composition sensor/bracket off to the side.
  5. Using a flare nut wrench and backup wrench disconnect the fuel line fitting from the fuel filter.
  6. Pull the quick connect fitting back until the internal retainers hit the filter stop.
  7. Twist one end of J-46363 and insert it between the fitting and the filter.
  8. Twist the opposite end of J-46363 and insert it between the fitting and filter.
  9. Once J-46363 is inserted, ensure that J-46363 is parallel to the filter and fitting.
  10. While holding the filter, push the fitting towards the filter in order to disconnect the quick connect fitting.
  11. Remove the fitting from the filter.
  12. Remove J-46363 from the filter.
  13. Remove the fuel filter from the bracket.
  1. Install the NEW fuel filter to the bracket.
  2. While holding the filter, push the fitting towards the filter in order to connect the quick connect fitting.
  3. Using a flare nut wrench and backup wrench connect the fuel line fitting to the fuel filter.
  4. Position the fuel composition sensor/bracket into place. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  5. Install the fuel composition sensor bracket nuts. Tighten: Tighten the nuts to 17 N.m (13 lb ft).
  6. Lower the vehicle.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(ref-184136-S34482429492005082200000) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(ref-184136-S06681899592005082200000) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  4. Remove the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)»(ref-184136-S18154157322005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S37037982052005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)»(ref-184136-S09540970022005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis)»(ref-184136-S41207873652005082200000) .
  5. Remove the fuel tank shield bolts, if equipped.
  6. Remove the fuel tank shield, if equipped.
  7. Disconnect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  8. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
  12. Lower the fuel tank half way. When lowering the tank, ensure that the fill neck on the tank does not get hung up on the harness.
  13. Disconnect the electrical harness clip at the frame crossmember.
  14. Lower the fuel tank until the electrical connections are accessible.
  15. Disconnect the fuel pressure sensor electrical connector.
  16. Disconnect the fuel sending unit electrical connector, perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
  17. Completely lower the fuel tank.
  18. With the aid of an assistant, place the fuel tank in a suitable work area.
  19. If necessary, disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
  20. If necessary, disconnect and remove the EVAP purge line (2) from the retaining clips.
  21. If necessary, disconnect and remove the EVAP fuel level vent valve (FLVV) line from the FLVV, sending unit, and retaining clips.
  22. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. If necessary, install and connect the EVAP FLVV line to the FLVV, sending unit, and retaining clips.
  3. If necessary, install and connect the EVAP purge line (2) to the retaining clips.
  4. If necessary, install and connect the fuel feed line (1) to the sending unit and retaining clips.
  5. With the aid of an assistant, place the fuel tank onto the adjustable jack.
  6. Raise the fuel tank until the electrical connections can be made.
  7. Connect the fuel sending unit and pressure sensor electrical connectors.
  8. Completely raise the fuel tank. When raising the tank, ensure that the fill neck on the tank goes over the harness.
  9. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  10. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  11. Remove the adjustable jack from under the fuel tank.
  12. Remove the caps from the fuel and EVAP lines.
  13. Connect the fuel feed and EVAP lines. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  14. If necessary, install the fuel tank shield.
  15. If necessary, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  16. Install the EVAP canister vent solenoid. Refer to «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup)»(ref-184136-S18154157322005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S37037982052005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (1500 Crew Cab)»(ref-184136-S09540970022005082200000) or «Evaporative Emission (EVAP) Canister Vent Solenoid Valve Replacement (Cab/Chassis)»(ref-184136-S41207873652005082200000) .
  17. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  18. Refill the fuel tank.
  19. Install the fuel cap.
  20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  21. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(ref-184136-S34482429492005082200000) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(ref-184136-S06681899592005082200000) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  4. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  5. If equipped, remove the fuel tank shield bolts.
  6. If equipped, remove the fuel tank shield.
  7. Disconnect the fuel feed and return line quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  8. Cap the fuel lines in order to avoid possible system contamination.
  9. Place a suitable adjustable jack under the fuel tank.
  10. Remove the fuel tank strap bolts.
  11. Remove the fuel tank straps.
  12. Lower the fuel tank until the electrical connections are accessible.
  13. Remove the fuel sending unit connector position assurance (CPA) retainer.
  14. Disconnect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  15. Completely lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, disconnect and remove the fuel feed (3) and return (2) pipes from the sending unit and retaining clips.
  18. If necessary, disconnect and remove the EVAP pipe (1) from the sending unit, roll over valve (3), and retaining clip.
  19. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. If necessary, install and connect the EVAP pipe (1) to the sending unit, roll over valve (3), and retaining clip.
  3. If necessary, install and connect the fuel feed (3) and return (2) pipes to the sending unit and retaining clips.
  4. With the aid of an assistant, place the fuel tank on the jack.
  5. Raise the fuel tank until the electrical connections can be made.
  6. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  7. Install the fuel sending unit CPA retainer.
  8. Completely raise the fuel tank.
  9. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  10. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  11. Remove the adjustable jack from under the fuel tank.
  12. Remove the caps from the fuel lines.
  13. Connect the fuel feed and return line quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  14. Install the fuel feed and return lines to the clip on the fuel tank.
  15. If equipped, install the fuel tank shield.
  16. If equipped, install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  17. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  18. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  19. Refill the fuel tank.
  20. Install the fuel cap.
  21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  22. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(ref-184136-S34482429492005082200000) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(ref-184136-S06681899592005082200000) .
  3. Remove the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  4. Remove the fuel tank shield bolts and shield, if necessary.
  5. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  6. Disconnect the fuel feed line from the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  7. Cap the fuel and EVAP lines in order to prevent possible system contamination.
  8. Place an adjustable jack under the fuel tank.
  9. Remove the fuel tank strap bolts.
  10. Remove the fuel tank straps.
  11. Remove the harness clip from the frame.
  12. Lower the fuel tank under the electrical connectors are accessible.
  13. Disconnect the fuel tank pressure sensor (1) electrical connector.
  14. Disconnect the fuel tank sending unit (2) electrical connector, perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
  15. Completely lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. With the aid of an assistant, place the fuel tank on a adjustable jack.
  3. Raise the fuel tank until the electrical connections can be made.
  4. Connect the fuel tank sending unit (2) electrical connector. Engage the gray retainer.
  5. Connect the fuel tank pressure sensor (1) electrical connector.
  6. Completely raise the fuel tank.
  7. Install the harness clip to the frame.
  8. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  9. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  10. Remove the adjustable jack from under the fuel tank.
  11. Remove the caps from the fuel and EVAP lines.
  12. Connect the fuel feed line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  13. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  14. Install the fuel tank shield and bolts, if necessary. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  15. Install the fuel tank fill pipe. Refer to «Filler Tube Replacement (Pickup)»(ref-184136-S20795539652005082200000) or «Filler Tube Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S42575643592005082200000) or «Filler Tube Replacement (1500 Crew Cab)»(ref-184136-S35535114782005082200000) or «Filler Tube Replacement (Cab/Chassis - Front)»(ref-184136-S15634658062005082200000) or «Filler Tube Replacement (Cab/Chassis - Rear)»(ref-184136-S25043793822005082200000) .
  16. Refill the fuel tank.
  17. Install the fuel cap.
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  19. Perform the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination.

Scheme 44

Scheme 44
Scheme 44
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. If equipped with a rear auxiliary tank, disconnect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
  4. Loosen the fuel fill pipe clamp (2) at the tank.
  5. Loosen the vent pipe clamp (1) at the tank.
  6. Remove the fuel fill pipe and vent pipe from the tank.
  7. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(ref-184136-S34482429492005082200000) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(ref-184136-S06681899592005082200000) .
  8. Disconnect the fuel pressure sensor electrical connector (1).
  9. Disconnect the fuel sending unit electrical connector (1), perform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
  10. Remove the canister vent solenoid (CVS) line from the fuel tank clips.
  11. Disconnect the fuel feed and EVAP quick connect fittings from the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  13. Remove the fuel tank shield bolts.
  14. Remove the fuel tank shield.
  15. Place a suitable adjustable jack under the fuel tank.
  16. Remove the fuel tank strap bolts.
  17. Remove the fuel tank straps.
  18. Lower the fuel tank.
  19. With the aid of an assistant, place the fuel tank in a suitable work area.
  20. Cap the fuel and EVAP pipes in order to prevent possible system contamination.
  21. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. Remove the caps from the fuel and EVAP pipes.
  3. With the aid of an assistant, place the fuel tank on the jack.
  4. Raise the fuel tank.
  5. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  6. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  7. Remove the jack from under the fuel tank.
  8. Install the fuel tank shield.
  9. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  10. Lower the vehicle.
  11. Connect the fuel feed and EVAP quick connect fittings to the sending unit. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Connect the fuel sending unit and fuel pressure sensor electrical connectors (1).
  13. Install the CVS line to the fuel tank clips.
  14. Install the fuel fill pipe and vent pipe to the tank.
  15. Tighten the vent pipe clamp (1) at the tank.
  16. Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  17. Remove the caps from the fuel feed and EVAP pipes.
  18. If equipped with a rear auxiliary tank, connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  19. Refill the fuel tank.
  20. Install the fuel fill cap.
  21. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) .
  22. Perform the following steps in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel and evaporative emission (EVAP) connections and surrounding area prior to disconnecting the lines in order to avoid possible system contamination.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Loosen the fuel fill pipe hose clamp (2) at the tank.
  3. Loosen the fuel vent pipe hose clamp (1) at the tank.
  4. Remove the fuel fill and vent hoses from the tank.
  5. Drain the fuel tank. Refer to «Fuel Tank Draining Procedure (4.8L, 5.3L, and 6.0L Engine)»(ref-184136-S34482429492005082200000) or «Fuel Tank Draining Procedure (5.3L (L59) Engine)»(ref-184136-S06681899592005082200000) .
  6. Disconnect the fuel tank pressure sensor electrical connector.
  7. Disconnect the fuel feed and EVAP (evaporative emission) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  8. Cap the fuel/EVAP lines in order to prevent possible system contamination.
  9. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  10. Remove the fuel tank shield bolts.
  11. Remove the fuel tank shield.
  12. Place a suitable adjustable jack under the fuel tank.
  13. Remove the fuel tank strap bolts.
  14. Remove the fuel tank straps.
  15. Lower the fuel tank.
  16. With the aid of an assistant, place the fuel tank in a suitable work area.
  17. If necessary, remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. If necessary, install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. With the aid of an assistant, place the fuel tank on the jack.
  3. Raise the fuel tank.
  4. Install the fuel tank straps. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  5. Install the fuel tank strap bolts. Tighten: Tighten the bolts to 40 N.m (30 lb ft).
  6. Remove the jack from under the fuel tank.
  7. Install the fuel tank shield.
  8. Install the fuel tank shield bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  9. Lower the vehicle.
  10. Remove the caps from the fuel/EVAP lines.
  11. Connect the fuel feed and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Connect the fuel tank pressure sensor electrical connector.
  13. Install the fuel fill and vent hoses to the tank.
  14. Tighten the fuel vent pipe hose clamp (1) at the tank.
  15. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  16. Refill the fuel tank.
  17. Install the fuel fill cap.
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  19. Perform the following steps in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Using a slight rocking motion, while pulling straight up, remove the fuel tank pressure sensor (1).
  1. Install the fuel tank pressure sensor (1).
  2. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. Disconnect the fuel pump electrical connector.
  3. Remove the fuel lever sensor electrical connector retaining clip.
  4. Disconnect the fuel level sensor electrical connector.
  5. Remove the fuel level sensor retaining clip.
  6. Remove the fuel level sensor (1).
  1. Install the fuel level sensor (1).
  2. Install the fuel level sensor retaining clip.
  3. Connect the fuel level sensor electrical connector.
  4. Install the fuel lever sensor electrical connector retaining clip.
  5. Connect the fuel pump electrical connector.
  6. Install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. Remove the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  2. Disconnect the fuel pump electrical connector.
  3. Remove the fuel level sensor electrical connector retaining clip.
  4. Disconnect the fuel level sensor electrical connector.
  5. Remove the fuel level sensor retaining clip.
  6. Remove the fuel level sensor.
  1. Install the fuel level sensor.
  2. Install the fuel level sensor retaining clip.
  3. Connect the fuel level sensor electrical connector.
  4. Install the fuel level sensor electrical connector retaining clip.
  5. Connect the fuel pump electrical connector.
  6. Install the sending unit. Refer to «Fuel Sender Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S29525971742005082200000) or «Fuel Sender Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S15118500402005082200000) .
  1. Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  5. Remove the fuel tank fill pipe ground wire bolt (1).
  6. Remove the fuel tank fill pipe ground wire (3) anti-rotation tab from the frame hole.
  7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (2).
  8. Open the axle vent hose clip on the fuel fill pipe bracket.
  9. Remove the rear axle vent hose from the clip.
  10. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
  11. Disconnect the recirculation line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  12. Remove the fuel tank fill pipe.
  13. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.
  3. Connect the recirculation line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) . NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  6. Close the axle vent hose clip.
  7. Position the fuel tank fill pipe ground wire and chassis harness ground wire (2).
  8. Install the fuel tank fill pipe ground wire (3) anti-rotation tab into the frame hole.
  9. Install the fuel tank fill pipe ground wire bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  10. Lower the vehicle.
  11. Install the fuel tank filler housing.
  12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  13. Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  1. Remove the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolt.
  3. Remove the fuel tank filler housing.
  4. Raise and suitably support the vehicle half way. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  5. Open the axle vent hose clip on the fuel fill pipe bracket.
  6. Remove the rear axle vent hose from the clip.
  7. Remove the fuel tank ground wire bolt (2).
  8. Reposition the fuel tank fill pipe ground wire.
  9. Loosen the fuel tank fill pipe clamp (3) at the fuel tank.
  10. Loosen the vent hose clamp (1) at the fuel tank.
  11. Remove the fuel tank fill pipe.
  12. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Tighten the vent hose clamp (1) at the fuel tank.
  4. Tighten the fuel tank fill pipe clamp (3) at the fuel tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  5. Position the fuel tank fill pipe ground wire.
  6. Install the fuel tank ground wire bolt (2). Tighten: Tighten the bolt to 9 N.m (80 lb in).
  7. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
  8. Close the axle vent hose clip.
  9. Install the fuel tank filler housing.
  10. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  11. Install the fuel tank filler housing to body TORX® screws (1) and pushpin retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  1. Remove the fuel tank filler housing to body TORX® screws (1) and retainer (2).
  2. Remove the fuel tank filler housing to fuel tank fill pipe bolts.
  3. Remove the fuel tank filler housing.
  4. Partially raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  5. Remove the fuel tank fill pipe ground wire bolt.
  6. Remove the fuel tank fill pipe ground wire from the frame.
  7. Loosen the fuel tank fill pipe clamp at the fuel tank.
  8. Disconnect the recirculation line quick connect fitting at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  9. Remove the fuel tank fill pipe.
  10. Cap the opening on the fuel tank in order to prevent possible system contamination.
  1. Remove the cap from the opening on the fuel tank.
  2. Install the fuel tank fill pipe.
  3. Connect the recirculation line quick connect fitting at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) . NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Tighten the fuel tank fill pipe clamp at the fuel tank. Tighten: Tighten the clamp to 2.5 N.m (22 lb in).
  5. Position the fuel tank fill pipe ground wire to the frame. Ensure the anti-rotation tab is positioned correctly.
  6. Install the fuel tank fill pipe ground wire bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  7. Lower the vehicle.
  8. Install the fuel tank filler housing.
  9. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten: Tighten the bolts to 2.3 N.m (20 lb in).
  10. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2). Tighten: Tighten the screws to 2.3 N.m (20 lb in).
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel feed and EVAP pipes in order to prevent possible system contamination.
  4. Loosen the fuel fill pipe clamp (2) at the tank.
  5. Loosen the vent pipe clamp (1) at the tank.
  6. Remove the fuel fill pipe and vent pipe from the tank.
  7. Cap the fuel and vent openings in the tank in order to prevent possible system contamination.
  1. Remove the caps from the fuel and vent openings in the tank.
  2. Install the fuel fill pipe and vent pipe to the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Tighten the vent pipe clamp (1) at the tank.
  4. Tighten the fuel fill pipe clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  5. Remove the caps from the fuel feed and EVAP pipes.
  6. If equipped with a rear auxiliary tank, connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Loosen the fuel fill pipe hose clamp (2) at the tank.
  3. Loosen the fuel vent pipe hose clamp (1) at the tank.
  4. Remove the fuel fill and vent hoses from the tank.
  1. Install the fuel fill and vent hoses to the tank.
  2. Tighten the fuel vent pipe hose clamp (1) at the tank. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Tighten the fuel fill pipe hose clamp (2) at the tank. Tighten: Tighten the clamps to 2.5 N.m (22 lb in).
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect the fuel line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Disconnect the evaporative emission (EVAP) line from the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Using J 45722 remove the sending unit lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  5. Remove the sending unit and seal. Discard the seal.
  6. Clean the sending unit sealing surfaces.
CAUTIONIn order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
IMPORTANTThe fuel strainer must be in a horizontal position when installing the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm.
  1. Install a NEW sending unit seal.
  2. Install the sending unit.
  3. Using J 45722 install the sending unit lock ring.
  4. Connect the EVAP line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Connect the fuel line to the sending unit. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  6. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect fuel lines from the sending unit, if required. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Using J 44402 , remove the sending unit lock ring.
  4. Remove the sending unit and seal. Discard the seal. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
  5. Clean the sending unit sealing surfaces.
CAUTIONIn order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.
IMPORTANTThe fuel strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel strainer does not block full travel of the float arm.
  1. Install a NEW sending unit seal.
  2. Align the tab, and install the sending unit.
  3. Using J 44402 , install the sending unit lock ring.
  4. Connect fuel lines to the sending unit, if required. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
  9. Remove the fuel line clip from the bracket on the transmission.
  10. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  11. Remove the clip from the bracket on the frame.
  12. Remove the transfer case harness from the clip bracket.
  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. If equipped with 4WD, remove the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  19. Disconnect the fuel and EVAP lines at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  20. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  21. Remove the fuel and EVAP bundle clip nuts.
  22. Remove the fuel and EVAP bundle.
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle clip nuts. Tighten: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  6. Install the EHCU (1).
  7. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  8. Connect the brake lines to the BPMV. Tighten: 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 equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  13. Install the fuel line clips to the brackets on the transmission.
  14. Install the HO2S sensor connector to the bracket.
  15. Install the fuel pipe bracket to the bellhousing stud.
  16. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  17. Lower the vehicle.
  18. Remove the caps from the fuel rail and EVAP line.
  19. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  20. Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Install the fuel fill cap.
  22. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  23. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the evaporative emission (EVAP) canister purge tube (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut (2).
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
  9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission.
  10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  11. Remove the clip from the bracket on the frame.
  12. Remove the transfer case harness from the clip bracket.
  13. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  14. Thoroughly wash all contaminants from around the EHCU.
  15. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
  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. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  20. Disconnect the fuel feed and return pipes at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Cap the fuel pipes at the fuel tank.
  22. If vehicle is a regular cab, remove the fuel feed, EVAP, and return pipe assembly nuts.
  23. If vehicle is a crew or extended cab, remove the fuel feed, EVAP, and return pipe assembly nuts.
  24. Remove the fuel feed, EVAP, and return pipe assembly.
  1. Install the fuel feed, EVAP, and return pipe assembly. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. If vehicle is a crew or extended cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. If vehicle is a regular cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  4. Remove the caps from the fuel pipes at the fuel tank.
  5. Connect the fuel feed and return pipes at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  6. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  7. Install the EHCU (1).
  8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  9. Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
  10. Connect the chassis electrical harness connectors to the EBCM.
  11. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  12. Install the transfer case harness to the clip bracket.
  13. Install the clip to the bracket on the frame.
  14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  15. Install the fuel hose/pipe clip to the bracket on the automatic transmission.
  16. Install the HO2S sensor connector to the bracket.
  17. Install the fuel pipe bracket to the bellhousing stud.
  18. Install the fuel pipe bracket nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
  19. Lower the vehicle.
  20. Remove the caps from the fuel rail and EVAP pipes.
  21. Connect the EVAP canister purge tube (3). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  22. Connect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  23. Install the fuel fill cap.
  24. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  25. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  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.
  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. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  19. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  20. Disconnect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  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.
  1. Install the fuel/EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel/EVAP bundle clip nuts. Tighten: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  6. Install the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  7. Install the EHCU (1).
  8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  9. Connect the brake lines to the BPMV. Tighten: 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: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Connect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the fuel line clips from the brackets on the transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  10. Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  12. Remove the EVAP line from the clips (2) on the fuel tank.
  13. Disconnect the quick connect fittings from the EVAP canister.
  14. Remove the fuel and EVAP bundle nuts.
  15. Remove the fuel and EVAP bundle.
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Connect the quick connect fittings to the EVAP canister.
  4. Install the EVAP line to the clips (2) on the fuel tank.
  5. Remove the caps from the fuel and EVAP lines.
  6. Connect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  7. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  8. Install the fuel line clips to the brackets on the transmission.
  9. Install the fuel pipe bracket to the bellhousing stud.
  10. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  11. Lower the vehicle.
  12. Remove the caps from the fuel rail.
  13. Connect the EVAP canister purge tube line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  14. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  15. Install the fuel fill cap.
  16. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  17. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  4. Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  6. Remove the rear fuel line bundle clip nuts.
  7. Remove the rear fuel line bundle.
  1. Install the rear fuel line bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the rear fuel line bundle clip nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. Remove the caps from the fuel and balance lines at the fuel tank.
  4. Connect the fuel feed and pressure balance lines to the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Remove the caps from the fuel and balance lines at the fuel tank.
  6. Connect the fuel feed and pressure balance lines to the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  7. Install the fuel fill cap.
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  9. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean the fuel feed pipe connection and surrounding area prior to disconnecting the fitting in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the fuel feed line (1) from the sending unit and retaining clips.
  3. Cap the fuel feed and evaporative emission (EVAP) openings in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the fuel feed (1) line to the sending unit and retaining clips.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean the fuel feed/return pipes connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the fuel feed (3) and/or fuel return (2) line from the sending unit and retaining clips.
  3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the fuel feed (3) and/or fuel return (2) line to the sending unit and retaining clips.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean the fuel feed pipe connection and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the fuel feed (1) line from the sending unit and retaining clips.
  3. Cap the fuel feed/return, and evaporative emission (EVAP) lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the fuel feed (1) line to the sending unit and retaining clips.
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTAn 8-digit identification number (1) is located on the fuel rail. Refer to this identification number when servicing or when part replacement is required.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Remove the wire harness bracket nut (2).
  3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
  4. Disconnect the generator electrical connector (3).
  5. Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Knock sensor (2)
  6. Remove the knock sensor harness connector from the intake manifold.
  7. Disconnect the electronic throttle control (ETC) electrical connector (2), preform the following: Disengage the gray retainer. Push down the black clip. Disconnect the connector.
  8. Remove the connector position assurance (CPA) retainer (5).
  9. Disconnect the following electrical connectors from the right side of the engine: Main coil (4) Fuel injectors (3)
  10. Remove the harness clips from the fuel rail (1).
  11. Remove the CPA retainer from the left side of the engine.
  12. Disconnect the following electrical connectors from the left side of the engine: Main coil (2) Fuel injectors
  13. Remove the harness clips from the fuel rail (1).
  14. Reposition the engine wire harness aside.
  15. Perform the following steps in order to disconnect the fuel injector electrical connectors. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. Push the tab (1) on the connector in. Disconnect the fuel injector electrical connector. Repeat the steps for each injector electrical connector.
  16. Remove the positive crankcase ventilation (PCV) hose.
  17. Disconnect the fuel feed pipe (1) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  18. Remove the fuel rail bolts.
  19. Remove the fuel rail.
  20. Remove the fuel injector lower O-ring seal (4) from each injector, if necessary.
  21. Discard the O-ring seal.
  1. Lubricate NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.
  3. Install the fuel rail.
  4. Apply a 5 mm (0.2 in) band of threadlock GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads of the fuel rail bolts.
  5. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  6. Connect the fuel feed pipe (1) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  7. Install the PCV hose.
  8. Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) on the connector in 1 click. Repeat the steps for each injector electrical connector.
  9. Position the engine wire harness.
  10. Connect the following electrical connectors to the left side of the engine: Main coil (2) Fuel injectors
  11. Install the harness clips to the fuel rail (1).
  12. Install the CPA retainer.
  13. Connect the following electrical connectors to the right side of the engine: Main coil (4) Fuel injectors (3)
  14. Install the CPA retainer (5).
  15. Install the harness clips to the fuel rail (1).
  16. Connect the ETC electrical connector (2), preform the following: Connect the connector. Engage the gray retainer.
  17. Connect the following electrical connectors: MAP sensor (1) Knock sensor (2)
  18. Install the knock sensor harness connector to the intake manifold.
  19. Connect the EVAP purge solenoid electrical connector (1).
  20. Connect the generator electrical connector (3).
  21. Install the wire harness bracket nut (2). Tighten: Tighten the nut to 5 N.m (44 lb in).
  22. Tighten the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Remove the wire harness bracket nut (2).
  3. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).
  4. Disconnect the generator electrical connector (3).
  5. Disconnect the following electrical connectors: Manifold absolute pressure (MAP) sensor (1) Knock sensor (2)
  6. Remove the knock sensor harness connector from the intake manifold.
  7. Remove the connector position assurance (CPA) retainer.
  8. Disconnect the following electrical connectors from both sides of the engine: Main coil (2) Fuel injectors
  9. Remove the harness clips from the fuel rail (1).
  10. Reposition the upper engine wire harness aside.
  11. Perform the following steps in order to disconnect the fuel injector electrical connectors: IMPORTANT: When disconnecting the Multec® 2 fuel injector connectors, DO NOT use pliers or other hand tools, as the connector ends may become mangled and be rendered unusable. Mark the connectors to their corresponding injectors to ensure correct reassembly. Pull the connector position assurance (CPA) retainer (2) on the connector up 1 click. Push the tab (1) on the connector in. Disconnect the fuel injector connector electrical connector. Repeat the steps for each injector connector.
  12. Remove the positive crankcase ventilation (PCV) hose.
  13. Disconnect the fuel feed and return pipes (1, 2) from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  14. Disconnect the fuel pressure regulator vacuum line.
  15. Remove the fuel rail bolts.
  16. Remove the fuel rail.
  17. Remove the fuel injector lower O-ring seal (4) from each fuel injector, if necessary.
  18. Discard the O-ring seal.
  1. Lubricate the NEW fuel injector lower O-ring seals (4) with clean engine oil.
  2. Install the NEW O-ring seals (4) onto each injector, if necessary.
  3. Install the fuel rail.
  4. Apply a 5 mm (0.020 in) band of threadlock, GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the threads of the fuel rail bolts.
  5. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  6. Connect the fuel pressure regulator vacuum line.
  7. Connect the fuel feed and return pipes (1, 2) to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  8. Install the PCV hose.
  9. Perform the following steps in order to connect the fuel injector electrical connectors. Install the connectors to their corresponding injectors to ensure correct reassembly. Connect the fuel injector electrical connector. Push the CPA retainer (2) in the connector in 1 click. Repeat the steps for each injector electrical connector.
  10. Position the engine wire harness.
  11. Connect the following electrical connectors to both sides of the engine: Main coil (2) Fuel injectors
  12. Install the harness clips to the fuel rail (1).
  13. Install the CPA retainers.
  14. Connect the following electrical connectors: MAP sensor (1) Knock sensor (2)
  15. Install the knock sensor harness connector to the intake manifold.
  16. Connect the EVAP purge solenoid electrical connector (1).
  17. Connect the generator electrical connector (3).
  18. Install the wire harness bracket nut (2). Tighten: Tighten the nut to 5 N.m (44 lb in).
  19. Tighten the fuel fill cap.
  20. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  21. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTThe fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) engine is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly, this includes both left and right rail assemblies and crossover pipe rail.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
  4. Remove the fuel return pipe (1).
  5. Remove and discard the fuel return pipe O-ring (6).
  6. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25).
  7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
  8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
  9. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15).
  10. Remove and discard the crossover fuel pipe O-rings (7, 20).
  1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
  2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
  3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15). NOTE: Refer to Fastener Notice in Cautions and Notices. IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
  4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22).
  5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
  6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3). IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4). Tighten: Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in). Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).
  10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
  11. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Install the fuel fill cap.
  13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  14. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTThe fuel pressure regulator retaining clip is specific to the fuel rail-regulator design and cannot be interchanged.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Remove the fuel pressure regulator vacuum hose.
  3. Clean any dirt from the fuel pressure regulator retainer and surrounding area.
  4. Remove the fuel pressure regulator retainer (8).
  5. Remove the fuel pressure regulator (9).
  6. Ensure none of the following parts are still in the fuel rail. Backup ring (10) Regulator seal O-ring (11) Regulator filter (12) Regulator seal O-ring (13)
  1. Ensure that the NEW fuel pressure regulator retainer is the correct one.
  2. The tab (1) is used on the E85-straight vacuum port retainer (3).
  3. Install the following parts onto the fuel pressure regulator (9), if necessary. Backup ring (10) Regulator seal O-ring (11) Regulator filter (12) Regulator seal O-ring (13)
  4. Lubricate the fuel pressure regulator O-rings (11, 13) with clean engine oil.
  5. Install the fuel pressure regulator (9). IMPORTANT: Whenever the fuel pressure regulator is removed from the fuel rail NEW O-rings and a NEW retaining clip should be used on reinstallation.
  6. Install the NEW fuel pressure regulator retainer (8).
  7. Install the fuel pressure regulator vacuum hose.
  8. Install the fuel fill cap.
  9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  10. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.

Note. Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

IMPORTANTThe engine oil may be contaminated with fuel if the fuel injectors are leaking.
  1. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S32994254792005082200000) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S32869786092005082200000) .
  2. Remove and discard the fuel injector retainer clip (19).
  3. Remove the fuel injector (17).
  4. Remove and discard the fuel injector retainer clip (1).
  5. Remove and discard the fuel injector O-ring seals (2, 4).
IMPORTANTWhen ordering new fuel injectors, you must order the correct injector for the application being serviced.

The fuel injector (1) is stamped with a identification part number (2). A four-digit build date code (3) indicates the month (4), day (5), year (6), and shift (7) that built the injector.

Scheme 45

Scheme 45
Scheme 45
  1. Lubricate the NEW injector O-ring seals (2, 4) with clean engine oil.
  2. Install the NEW injector O-ring seals onto the fuel injector.
  3. Install a NEW retainer clip (1) onto the fuel injector.
  4. Push the fuel injector (17) into the fuel rail injector socket with the electrical connector facing outward. The retainer clip (19) locks on to a flange on the fuel rail injector socket.
  5. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184136-S32994254792005082200000) or «Fuel Rail Assembly Replacement (5.3L (L59) Engine)»(ref-184136-S32869786092005082200000) .
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  2. Remove the evaporative emission (EVAP) line from the canister purge solenoid, perform the following: Push the large size white retainer portion in. Push down, while pulling up slightly in order the disengage the tube.
  3. Disconnect the EVAP canister purge solenoid electrical connector (1).
  4. Remove the EVAP canister purge solenoid bolt (2).
  5. Remove the EVAP canister purge solenoid (3) and insulator (1).
  1. Install the insulator (1) onto the EVAP canister purge solenoid (3).
  2. Install the EVAP canister purge solenoid (3). NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the EVAP canister purge solenoid bolt (2). Tighten: Tighten the bolt to 10.5 N.m (93 lb in).
  4. Connect the EVAP canister purge solenoid electrical connector (1).
  5. Install the EVAP line to the canister purge solenoid (1).
  6. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
IMPORTANTClean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Remove the harness clip from the canister vent solenoid (CVS) line.
  3. Disconnect the CVS electrical connector.
  4. If the vehicle is equipped with a 6 ft box, disconnect the EVAP CVS line from the canister.
  5. Remove the CVS clip from the frame crossmember.
  6. Push in the retainer and remove the CVS from the fuel tank clip.
  7. If the vehicle is equipped with a 8 ft box, disconnect the EVAP CVS line from the canister.
  8. Remove the CVS clip from the frame crossmember.
  9. Push in the retainer and remove the CVS from the fuel tank clip.
  1. If the vehicle is equipped with a 8 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 8 ft box, the CVS line is routed below the frame crossmember.
  2. Install the CVS clip to the frame crossmember.
  3. Connect the EVAP CVS line to the canister.
  4. If the vehicle is equipped with a 6 ft box, install the CVS to the fuel tank until the clip engages. IMPORTANT: On vehicles equipped with a 6 ft box, the CVS line is routed above the frame crossmember.
  5. Install the CVS clip to the frame crossmember.
  6. Connect the EVAP CVS line to the canister.
  7. Connect the CVS electrical connector.
  8. Install the harness clip to the canister vent solenoid (CVS) line.
  9. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) pipe connections and surrounding areas before disconnecting the pipe in order to avoid possible EVAP system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect the EVAP vent valve electrical connector (1).
  3. Open the pipe retaining clips.
  4. Remove the EVAP vent valve bracket bolt.
  5. Remove the EVAP pipe from the retaining clips.
  6. Remove the EVAP vent valve with pipe.
  1. Install the EVAP vent valve with pipe.
  2. Install the EVAP pipe to the retaining clips. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the EVAP vent valve bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  4. Close the pipe retaining clips.
  5. Connect the EVAP vent valve electrical connector (1).
  6. Lower the vehicle.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the canister vent solenoid (CVS) electrical connector (1).
  3. Remove the CVS bracket bolt.
  4. Disconnect the CVS line from the evaporative emission (EVAP) canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Remove the CVS from the vehicle.
  6. If necessary, remove the CVS from the CVS bracket.
  1. If necessary, install the CVS to the CVS bracket.
  2. Install the CVS to the vehicle. Ensure the locator tab is inserted into the frame hole.
  3. Connect the CVS line to the canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) . NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Install the CVS bracket bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
  5. Connect the CVS electrical connector (1).
  6. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas before disconnecting the line in order to avoid possible EVAP system contamination.
  1. Disconnect the EVAP canister vent solenoid (CVS) electrical connector (1).
  2. Remove the EVAP CVS valve bracket bolt (1).
  3. Remove the EVAP CVS line from the clips on the fuel tank.
  4. Remove the CVS valve and line.
  5. Remove the EVAP CVS valve line from the CVS, if necessary.
  1. Install the EVAP CVS valve line to the CVS, if necessary.
  2. Install the CVS valve and line. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the EVAP CVS valve bracket bolt (1). Tighten: Tighten the bolt to 12 N.m (106 lb in).
  4. Install the EVAP CVS line to the clips on the fuel tank.
  5. Connect the EVAP CVS electrical connector (1).
IMPORTANTClean the evaporative emission (EVAP) pipe connections and surrounding area prior to disconnecting the fittings in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the EVAP purge line (2) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Disconnect and remove the EVAP fuel level vent valve (FLVV) line (3) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel feed and EVAP openings in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed and EVAP lines.
  2. Install and connect the EVAP FLVV line (3) line to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install and connect the EVAP purge line (2) to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the EVAP line (1) from the roll over valve, sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the EVAP line (1) to the roll over valve, sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel system contamination.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
  2. Disconnect and remove the EVAP rear line (2) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Disconnect and remove the EVAP line (3) from the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel feed/return, and EVAP lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel feed/return, and EVAP lines.
  2. Install and connect the EVAP line (3) to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install and connect the EVAP rear line (2) to the sending unit and retaining clips. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement (Pickup)»(ref-184136-S29946450192005082200000) or «Fuel Tank Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S28365747942005082200000) or «Fuel Tank Replacement (1500 Crew Cab)»(ref-184136-S03213408572005082200000) or «Fuel Tank Replacement (Cab/Chassis - Front)»(ref-184136-S04286373712005082200000) or «Fuel Tank Replacement (Cab/Chassis - Rear)»(ref-184136-S16320839262005082200000) .
IMPORTANTClean the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination.
  1. Remove the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
  2. Disconnect the EVAP tube from the EVAP canister purge solenoid (1). Push the large side white retainer portion in. Push down, while pulling up slightly in order to disengage the tube.
  3. Disconnect the EVAP tube from the chassis EVAP pipe (2). Push the large side white retainer portion in. Push down, while pulling up slightly in order to disengage the tube.
  4. Remove the EVAP tube.
  5. Cap the EVAP canister purge solenoid and EVAP chassis pipe in order to prevent possible EVAP system contamination.
  1. Remove the caps from the EVAP canister purge solenoid and EVAP chassis pipe.
  2. Install the EVAP tube.
  3. Connect the EVAP tube to the EVAP chassis pipe (2).
  4. Connect the EVAP tube to the EVAP purge solenoid (1).
  5. Install the engine sight shield. Refer to «Engine Sight Shield Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184187-S29824444452005082200000) or «Engine Sight Shield Replacement (6.0L Engine w/RPOs Y91 and Z88)»(ref-184187-S35316120602005082200000) in Engine Mechanical - 4.8L, 5.3L, and 6.0L.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube line (2).
  4. Cap the fuel rail in order to avoid possible system contamination.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut.
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the fuel line clips from the brackets on the transmission.
  9. If equipped with 4-wheel drive (4WD), remove the fuel line clip from the bracket on the transfer case.
  10. Disconnect the fuel and EVAP quick connect fittings. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  11. Cap the fuel and EVAP lines at the fuel tank in order to avoid possible system contamination.
  12. Remove the fuel and EVAP bundle nuts.
  13. Remove the fuel and EVAP bundle.
  1. Install the fuel and EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel and EVAP bundle nuts. Tighten: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. If equipped with 4WD, install the fuel line clip to the bracket on the transfer case.
  6. Install the fuel line clip(s) to the bracket(s) on the transmission.
  7. Install the fuel pipe bracket to the bellhousing stud.
  8. Install the fuel pipe bracket nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
  9. Lower the vehicle.
  10. Remove the cap from the fuel rail.
  11. Connect the fuel feed line (1) at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  12. Connect the EVAP canister purge tube line (2).
  13. Install the fuel fill cap.
  14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  15. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean all fuel pipe connections and surrounding areas before disconnecting the pipes in order to avoid possible fuel system contamination.
  1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the evaporative emission (EVAP) canister purge tube (3).
  4. Cap the fuel rail and EVAP pipes.
  5. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  6. Remove the fuel pipe bracket nut (2).
  7. Remove the fuel pipe bracket from the bellhousing stud.
  8. Remove the heated oxygen sensor (HO2S) sensor connector from the bracket.
  9. Remove the fuel hose/pipe clip from the bracket on the automatic transmission.
  10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case.
  11. Remove the clip from the bracket on the frame.
  12. Remove the transfer case harness from the clip bracket.
  13. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  14. Thoroughly wash all contaminants from around the EHCU.
  15. Disconnect the chassis electrical harness connectors from the electronic brake control module (EBCM).
  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. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  20. Disconnect the fuel feed and return pipes at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Cap the fuel pipes at the fuel tank.
  22. If vehicle is a regular cab, remove the fuel feed, EVAP, and return pipe assembly nuts.
  23. If vehicle is a crew or extended cab, remove the fuel feed, EVAP, and return pipe assembly nuts.
  24. Remove the fuel feed, EVAP, and return pipe assembly.
  1. Install the fuel feed, EVAP, and return pipe assembly. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. If vehicle is a crew or extended cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  3. If vehicle is a regular cab, install the fuel feed, EVAP, and return pipe assembly nuts. Tighten: Tighten the nuts to 12 N.m (106 lb in).
  4. Remove the caps from the fuel pipes at the fuel tank.
  5. Connect the fuel feed and return pipes at the fuel tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  6. If equipped with 4WD, install the torsion bar bracket. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  7. Install the EHCU (1).
  8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  9. Connect the brake lines to the BPMV. Tighten: Tighten the fittings to 25 N.m (18 lb ft).
  10. Connect the chassis electrical harness connectors to the EBCM.
  11. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  12. Install the transfer case harness to the clip bracket.
  13. Install the clip to the bracket on the frame.
  14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case.
  15. Install the fuel hose/pipe clip to the bracket on the automatic transmission.
  16. Install the HO2S sensor connector to the bracket.
  17. Install the fuel pipe bracket to the bellhousing stud.
  18. Install the fuel pipe bracket nut (2). Tighten: Tighten the nut to 10 N.m (89 lb in).
  19. Lower the vehicle.
  20. Remove the caps from the fuel rail and EVAP pipes.
  21. Connect the EVAP canister purge tube (3).
  22. Connect the fuel feed and return pipes (1) at the fuel rail. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  23. Install the fuel fill cap.
  24. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  25. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Disconnect the EVAP canister purge tube (2) fitting. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel rail and EVAP lines in order to avoid possible system contamination.
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  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 clips from the brackets 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.
  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. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  19. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  20. Disconnect the fuel line at the tank. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  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.
  1. Install the fuel/EVAP bundle. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the fuel/EVAP bundle clip nuts. Tighten: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  6. Install the torsion bar bracket, if equipped with 4WD. Refer to «Torsion Bar Replacement»(ref-184214-S16370331862005082200000) in Front Suspension.
  7. Install the EHCU (1).
  8. Install the bolts (4) attaching the EHCU bracket to the frame (5). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  9. Connect the brake lines to the BPMV. Tighten: 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 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: 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. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  21. Connect the fuel feed line (1) fitting at the engine. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  22. Install the fuel fill cap.
  23. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  24. Use the following procedure in order to inspect for leaks: Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean 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 Procedure»(ref-184136-S33630584752005082200000) .
  2. Disconnect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  3. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  4. Disconnect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Cap the fuel and balance lines at the fuel tank in order to avoid possible system contamination.
  6. Remove the rear fuel line bundle clip nuts.
  7. Remove the rear fuel line bundle.
  1. Install the rear fuel line bundle.
  2. Install the rear fuel line bundle clip nuts.
  3. Remove the caps from the fuel and balance lines at the fuel tank.
  4. Connect the fuel feed and pressure balance lines from the rear tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  5. Remove the caps from the fuel and balance lines at the fuel tank.
  6. Connect the fuel feed and pressure balance lines from the front tank. Refer to «Quick Connect Fitting(s) Service (Metal Collar)»(ref-184136-S17639071672005082200000) .
  7. Install the fuel fill cap.
  8. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
  9. Perform the following procedure in order to inspect for leaks. Turn the ignition ON, with the engine OFF, for 2 seconds. Turn the ignition OFF for 10 seconds. Turn the ignition ON, with the engine OFF. Inspect for fuel leaks.
IMPORTANTClean all the evaporative emission (EVAP) line connections and surrounding areas prior to disconnecting the fittings in order to avoid possible fuel/EVAP system contamination.
  1. Remove the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
  2. Remove the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Remove the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Cap the fuel and EVAP lines in order to prevent possible fuel/EVAP system contamination.
  1. Remove the caps from the fuel and EVAP lines.
  2. Install the EVAP canister purge line (2). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Install the EVAP canister line (1). Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Install the EVAP canister. Refer to «Evaporative Emission (EVAP) Canister Replacement (Pickup)»(ref-184136-S33680185422005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Pickup - 5.3L (L59) Engine)»(ref-184136-S20656068122005082200000) or «Evaporative Emission (EVAP) Canister Replacement (1500 Crew Cab)»(ref-184136-S35237422452005082200000) or «Evaporative Emission (EVAP) Canister Replacement (Cab/Chassis)»(ref-184136-S00003868682005082200000) .
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the EVAP canister vent solenoid (CVS) line from the EVAP canister.
  3. Disconnect the fuel tank EVAP line from the canister.
  4. Disconnect the canister EVAP line from the fuel bundle line.
  5. Remove the EVAP canister nut.
  6. Remove the EVAP canister with shield from the bracket.
  7. If necessary, remove the EVAP canister from the shield, perform the following: Lift up the retaining clip on the bottom of the canister. Remove the canister from the shield.
  8. If necessary, disconnect the EVAP lines from the canister.
  1. If necessary, connect the EVAP lines to the canister.
  2. If necessary, install the EVAP canister to the shield, perform the following: Install the canister to the shield. Ensure the retaining clip engages on the bottom of the canister.
  3. Install the EVAP canister with shield to the bracket. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Install the EVAP canister nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
  5. Connect the canister EVAP line to the fuel bundle line.
  6. Connect the fuel tank EVAP line to the canister.
  7. Connect the EVAP CVS line to the canister.
  8. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the EVAP canister vent solenoid (CVS) line from the canister.
  3. Disconnect the fuel tank EVAP line from the canister.
  4. Disconnect the canister EVAP line from the fuel bundle line.
  5. Remove the EVAP canister bolt.
  6. Remove the EVAP canister from the bracket.
  7. If necessary, disconnect the EVAP line from the canister and remove it from the retaining clip.
  1. If necessary, connect the EVAP line to the canister and install it to the retaining clip.
  2. Install the EVAP canister to the bracket. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  3. Install the EVAP canister bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  4. Connect the canister EVAP line to the fuel bundle line.
  5. Connect the fuel tank EVAP line to the canister.
  6. Connect the EVAP CVS line to the canister.
  7. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the canister vent solenoid (CVS) line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  3. Disconnect the fuel/EVAP bundle line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Disconnect the fuel tank line from the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Remove the EVAP canister bracket bolts.
  6. Remove the EVAP canister from the bracket, if necessary.
  1. Install the EVAP canister to the bracket, if necessary. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the EVAP canister bracket bolts. Tighten: Tighten the bolts to 18 N.m (13 lb ft).
  3. Connect the fuel tank line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  4. Connect the fuel/EVAP bundle line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  5. Connect the CVS line to the EVAP canister. Refer to «Quick Connect Fitting(s) Service (Plastic Collar)»(ref-184136-S07045263992005082200000) .
  6. Lower the vehicle.
IMPORTANTClean all evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.
  1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
  2. Disconnect the EVAP canister vent solenoid (CVS) line from the canister.
  3. Disconnect the fuel tank EVAP line from the canister.
  4. Disconnect the canister EVAP line from the fuel bundle line.
  5. Remove the EVAP canister nuts.
  6. Remove the EVAP canister.
  1. Install the EVAP canister. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  2. Install the EVAP canister nuts. Tighten: Tighten the nuts to 25 N.m (18 lb ft).
  3. Connect the canister EVAP line to the fuel bundle line.
  4. Connect the fuel tank EVAP line to the canister.
  5. Connect the EVAP CVS line to the canister.
  6. Lower the vehicle.
  1. If equipped with regular production option (RPO) HP2, disconnect the energy storage box (ESB). Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-184144-S17357825682005082200000) in Engine Electrical.
  2. Remove the spark plug wire from the ignition coil.
  3. Disconnect the ignition coil electrical connector.
  4. If equipped with regular production option (RPO) HP2, remove the auxiliary heater water pump bracket bolts.
  5. Remove the auxiliary heater water pump from the studs, and reposition out of the way.
  6. If equipped with RPO HP2, remove the starter/generator control module (SGCM) cover bolts, and cover.
  7. Remove the 3-phase cable nuts to the SGCM.
  8. Remove the 3-phase cable from the SGCM.
  9. If equipped with RPO HP2, remove the 3-phase cable bracket nuts (2).
  10. Remove the 3-phase cable bracket (1) from the studs, and reposition the cable and bracket out of the way.
  11. Remove the ignition coil bolts.
  12. Remove the ignition coil.
  1. Install the ignition coil.
  2. Install the ignition coil bolts. Tighten: Tighten the bolts to 8 N.m (71 lb in).
  3. If equipped with RPO HP2, position the cable (w/bracket) and install the 3-phase cable bracket to the studs.
  4. Install the 3-phase cable bracket nuts (2). Tighten: Tighten the nuts to 15 N.m (11 lb ft).
  5. If equipped with RPO HP2, install the 3-phase cable to the SGCM.
  6. Install the 3-phase cable nuts to the SGCM. Tighten: Tighten the nuts to 9 N.m (80 lb in).
  7. Install the SGCM cover and bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
  8. If equipped with RPO HP2, position the auxiliary heater water pump and install it onto the studs.
  9. Install the auxiliary heater water pump bracket bolts. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
  10. Connect the ignition coil electrical connector.
  11. Install the spark plug wire to the ignition coil.
  12. If equipped with RPO HP2, connect the ESB. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-184144-S17357825682005082200000) in Engine Electrical.
  1. Remove the spark plug wire from the spark plug. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the spark plug.
  2. Remove the spark plug wire from the ignition coil. Twist the spark plug wire boot a 1/2 turn. Pull only on the boot in order to remove the wire from the ignition coil.
  3. There are 2 different manufacturers for the spark plug wire, ignition coils and coil brackets. They are as follows
  4. The Melco® spark plug wire (1) will have a blue foil mark on it, and the wire is 145 mm (5.70 in) in length from cable seal to cable seal.
  5. The Delphi® spark plug wire (2) will have a white foil mark on it, and the wire is 110 mm (4.30 in) in length cable seal to cable seal.
  6. The Melco® (1) ignition coil is a square design.
  7. The Delphi® (2) ignition coil is a round design.
  8. The Melco® ignition coil bracket (1) is a square design.
  9. The Delphi® ignition coil bracket (2) is a round design.
  1. Install the spark plug wire to the ignition coil.
  2. Install the spark plug wire to the spark plug.
  3. Inspect the spark plug wire for proper installation: Push sideways on each boot in order to inspect the seating. Reinstall any loose boot.
  1. Correctly position the spark plug washer.
  2. Inspect the spark plug gap. Adjust the gap as needed. Specification: Spark plug gap: 1.016 mm (0.040 in)
  3. Hand start the spark plug in the corresponding cylinder. NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
  4. Tighten the spark plug. Tighten: Tighten the plug to 15 N.m (11 lb ft) for used heads. Tighten the plug to 20 N.m (15 lb ft) for NEW heads.
  5. Install the spark plug wire. Refer to «Spark Plug Wire Replacement»(ref-184136-S22902163132005082200000) .
IMPORTANTPerform the CKP System Variation Learn Procedure whenever the crankshaft position sensor is removed or replaced.
  1. Remove the starter. Refer to «Starter Motor Replacement (4.3L Engine)»(ref-184144-S07911227652005082200000) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S27615589722005082200000) or «Starter Motor Replacement (6.6L (LB7) Engine)»(ref-184144-S26643033962005082200000) or «Starter Motor Replacement (6.6L (LLY) Engine)»(ref-184144-S36072456772005082200000) or «Starter Motor Replacement (8.1L Engine)»(ref-184144-S42906435932005082200000) in Engine Electrical.
  2. Disconnect the crankshaft position (CKP) sensor electrical connector.
  3. Clean the area around the CKP sensor before removal in order to avoid debris from entering the engine.
  4. Remove the CKP sensor bolt.
  5. Remove the CKP sensor.
  1. Install the CKP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the CKP sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  3. Connect the CKP sensor electrical connector.
  4. Install the starter. Refer to «Starter Motor Replacement (4.3L Engine)»(ref-184144-S07911227652005082200000) or «Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184144-S27615589722005082200000) or «Starter Motor Replacement (6.6L (LB7) Engine)»(ref-184144-S26643033962005082200000) or «Starter Motor Replacement (6.6L (LLY) Engine)»(ref-184144-S36072456772005082200000) or «Starter Motor Replacement (8.1L Engine)»(ref-184144-S42906435932005082200000) in Engine Electrical.
  5. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(ref-184136-S28806049692005082200000) .
IMPORTANTClean the area around the camshaft position (CMP) sensor before removal in order to prevent debris from entering the engine.
  1. Remove the CMP sensor bolt.
  2. Remove the CMP sensor.
  1. Install the CMP sensor. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the CMP sensor bolt. Tighten: Tighten the bolt to 29 N.m (21 lb ft).
  1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-184187-S14258848172005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  2. Gently pry up the rubber covers.
  3. Disconnect the knock sensor electrical connectors.
  4. Remove the knock sensors.
  1. Install the knock sensors. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  2. Connect the knock sensor electrical connectors.
  3. Push down on the rubber covers.
  4. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-184187-S14258848172005082200000) in Engine Mechanical-4.8L, 5.3L, and 6.0L.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
  3. Loosen the air cleaner housing top screws.
  4. Remove the air cleaner housing cover.
  5. Remove the air filter element.
  1. Install a NEW air filter element.
  2. Install the air cleaner housing cover.
  3. Tighten the air cleaner housing top screws until snug.
  4. Connect the MAF/IAT sensor electrical connector (4).
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  2. Disconnect the mass air flow/intake air temperature (MAF/IAT) sensor electrical connector (4).
  3. Pull up on the air cleaner assembly (1) in order to release the retainers from the air cleaner adaptor (2).
  4. If necessary, loosen the MAF/IAT clamp.
  5. If necessary, remove the MAF/IAT sensor.
  1. If necessary, install the MAF/IAT sensor.
  2. If necessary, tighten the MAF/IAT clamp. Tighten: Tighten the clamp to 7 N.m (62 lb in).
  3. Position the air cleaner assembly (1) onto the air cleaner adaptor (2).
  4. Push down on the air cleaner assembly in order to secure the assembly to the adaptor.
  5. Connect the MAF/IAT sensor electrical connector (4).
  6. Install the air cleaner outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-184136-S31201114182005082200000) .
  1. Loosen the clamp and separate the air cleaner outlet duct at the mass air flow/intake air temperature (MAF/IAT) sensor.
  2. Loosen the clamp and separate the air cleaner outlet duct from the throttle body.
  3. Remove the radiator inlet hose clamp from the outlet duct.
  4. Remove the air cleaner outlet duct.
  1. Install the air cleaner outlet duct.
  2. Install the air cleaner outlet duct to the throttle body.
  3. Install the air cleaner outlet duct to MAF/IAT sensor.
  4. Install the radiator inlet hose clamp to the outlet duct. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Tighten the air cleaner outlet duct clamps. Tighten: Tighten the clamps to 4 N.m (35 lb in).
  1. Remove the front fender. Refer to «Fender Replacement - Front - Right»(ref-184166-S06955643872005082200000) in Body Front End.
  2. Place the fender in a safe location, in order not to damage it.
  3. Remove the lower intake air duct from the fender.
  1. Install the lower intake air duct to the fender. Insert the button (2) on the duct (1) into the slot on the fender inner panel extension.
  2. Install the front fender. Refer to «Fender Replacement - Front - Right»(ref-184166-S06955643872005082200000) in Body Front End.

More articles — Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)