Filler Tube Replacement Utility

1. Drain the fuel below the level of the fuel filler hose. Refer to Fuel Tank Draining .



2. Remove the fuel fill pipe housing to fuel fill pipe bolts.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



4. Disconnect the fuel fill pipe ground strap.



5. Disconnect the rear axle vent hose from the retainer on the fuel fill pipe.
6. Loosen the fuel vent hose (3) to fill tube clamp (2).
7. Disconnect the fuel vent hose (3) from the fill tube.



8. Loosen the fuel fill hose to fuel tank clamp (2).
9. Disconnect the fuel fill hose from the fuel tank.
10. Remove the fuel fill hose assembly.
11. Cap the open end of the fuel tank.

1. Uncap the fuel tank.

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.

2. Install the fuel fill hose assembly to the fuel tank.

Tighten
Tighten the fuel fill pipe clamp (2), to 2.5 N·m (22 lb in)




3. Connect the fuel fill vent hose (3) to the fill tube.

Tighten
Tighten the vent hose clamp (2), to 2.5 N·m (22 lb in)




4. Connect the fuel fill pipe ground strap.

Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N·m (80 lb in)

5. Connect the rear axle vent hose to the retainer on the fuel fill pipe.
6. Lower the vehicle.



7. Install the fuel fill pipe housing to the fuel fill pipe bolts.

Tighten
Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N·m (20 lb in)




8. Refill the fuel system.
9. Install the fuel filler cap.

Filler Tube Replacement Cab/Chassis

1. Drain the fuel below the level of the fuel filler hose. Refer to Fuel Tank Draining .



2. Remove the fuel fill pipe housing to fuel fill pipe bolts.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



4. Loosen the vent hose (1) to fuel tank clamp (5).
5. Disconnect the vent hose from the fuel tank.
6. Loosen the fuel fill hose to fuel tank clamp (3).
7. Disconnect the fuel fill hose from the fuel tank.
8. Remove the fuel fill and vent pipe and hose assembly.
9. Cap the open end of the fuel tank.

1. Uncap the fuel tank.
2. Install the fuel fill and vent pipe and hose assembly to the fuel tank.

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. Align the fuel fill pipe to the fuel fill pipe housing.

Tighten

•	Tighten the fuel fill hose clamp (3) to 2.5 N·m (22 lb in)

•	Tighten the vent hose clamp (5) to 2.5 N·m (22 lb in)

4. Lower the vehicle.



5. Install the fuel fill pipe housing to the fuel fill pipe bolts.

Tighten
Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N·m (20 lb in)

6. Refill the fuel system.
7. Install the fuel filler cap.