Filler Tube Replacement 2-Door Utility

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Raise the vehicle.
4. Wipe the vent hose connection at the fuel tank and then disconnect the vent hose and clamp (1).
5. Wipe the fuel filler hose connection at the fuel tank and then disconnect the fuel filler hose and clamp (2).



6. Remove the filler pipe ground strap bolt (4).



7. Remove the fuel fill pipe to fill pipe housing attaching screws.
8. Remove the fuel fill and vent pipes and hoses.

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 fill and vent pipes and hoses to the fuel tank and the fill pipe housing.

Tighten

•	Tighten the vent hose clamp (1) to 1.7 N·m (15 lb in).

•	Tighten the fuel fill hose clamp (2) to 2.5 N·m (22 lb in).




2. Connect the fill pipe ground strap to the frame with the bolt (4) and washer (3).

Tighten
Tighten the ground strap bolt to 15 N·m (11 lb ft).

3. Lower the vehicle.



4. Install the fuel fill pipe to fill pipe housing attaching screws.

Tighten
Tighten the fuel fill pipe to fill pipe housing screws to 1.9 N·m (17 lb in).

5. Install the fuel filler cap.
6. Connect the negative battery cable.
7. Inspect for leaks.

Filler Tube Replacement 4-Door Utility Lower

1. Drain the fuel from the fuel tank, leaving the lower fuel fill hose disconnected.
2. Remove the spare tire (underbody mounted spare tire only).



3. Loosen the upper fuel fill hose clamp (7).
4. Disconnect the ground wire (5) from the frame crossover.
5. Remove the ground wire retaining straps (6) from the lower fuel fill tube.



6. Remove the lower fuel fill tube retaining bolt from the frame crossover.



7. Disconnect the lower fuel fill tube (12) from the upper fuel fill hose (11).
8. Remove the fuel fill tube (12).

1. Position the fuel fill tube (12) over the frame crossover.
2. Connect both the upper (11) and lower (13) fuel fill hoses to the lower fuel fill tube (12).




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.

3. Install the lower fuel fill tube retaining bolt to the frame crossover.

Tighten
Tighten the fuel fill tube bracket retaining bolt to 15 N·m (11 lb ft).




4. Install the ground wire (5) to the frame crossover.

Tighten
Tighten the ground strap retaining screw to 15 N·m (11 lb ft).

5. Attach the ground wire to the lower fuel fill tube with new retaining straps (6).
6. Position the hose clamps (2, 7) on the upper (11) and lower (13) fuel fill hoses.

Tighten
Tighten the hose clamps (2, 7) to 2.5 N·m (22 lb in).

7. Install the spare tire (underbody mounted spare tire only).
8. Lower the vehicle.
9. Remove the fuel fill cap and refill the fuel tank.
10. Install the fuel fill cap.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Filler Tube Replacement Pickup

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
2. Remove the fuel filler cap.
3. Remove the fuel filler pipe housing attaching screws (1).
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Position an approved gasoline drain container under the fuel filler pipe.



6. Remove the ground strap bolt (1).
7. Cap the fuel tank openings in order to prevent possible fuel system contamination.
8. Loosen the hose clamps (2).
9. Remove the filler hose (3).

1. Remove the caps from the fuel tank openings.
2. Install the filler hose (3).

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.

3. Tighten the hose clamps (2).

Tighten
Tighten the fuel fill hose clamps to 2.5 N·m (22 lb in).

4. Install the ground strap bolt (1).

Tighten
Tighten the ground strap bolt to 15 N·m (133 lb in).




5. Install the fuel filler pipe housing attaching screws (1).

Tighten
Tighten the attaching screws to 1.9 N·m (133 lb in).

6. Refill the fuel system.
7. Install the fuel filler cap.
8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
9. Inspect for leaks.