Fuel Cooler Replacement Pickup

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Relieve the fuel pressure.
3. Disconnect the fuel pipes from the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
4. Remove the retaining bolts (4, 6) from the chassis and crossover.
5. Remove the fuel cooler (1).
6. Remove the fuel cooler support bracket (3) from the fuel cooler (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the fuel cooler support bracket (3) to the fuel cooler (1).

Tighten
Tighten the retaining bolt (5) to 18 N·m (13 lb ft).

2. Install the fuel cooler (1) to the chassis and crossover.

Tighten
Tighten the retaining bolts (4, 6 ) to 18 N·m (13 lb ft).

3. Connect the fuel pipes to the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
4. Lower the vehicle.
5. Purge the air from the fuel system. Refer to Fuel Feed Pipe and Return Pipe Purging .
6. Start the engine and inspect for fuel leaks.

Fuel Cooler Replacement Cab/Chassis

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



2. Disconnect the fuel pipes from the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
3. Remove the retaining nuts (2) from the chassis crossmember.
4. Remove the fuel cooler (1).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the fuel cooler (1) to the chassis crossmember.

Tighten
Tighten the retaining nuts to 40 N·m (30 lb ft).

2. Connect the fuel pipes to the fuel cooler (1). Refer to Metal Collar Quick Connect Fitting Service .
3. Lower the vehicle.
4. Purge the air from the fuel system. Refer to Fuel Feed Pipe and Return Pipe Purging .
5. Start the engine and inspect for fuel leaks.