Filler Tube Replacement Pickup

1. Remove the fuel tank filler housing to body screws (1), and retainer (2).



2. Remove the fuel tank filler housing to fuel tank fill pipe screws.
3. Remove the fuel tank filler housing.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



5. Remove the fuel tank ground strap bolt (3).
6. Remove the chassis harness ground strap (2) and fuel tank ground strap (4).



7. Remove the rear axle vent hose from the clip on the fuel fill pipe bracket.



8. Loosen the fuel tank fill pipe clamp.
9. Remove the fuel fill pipe from the tank and vehicle.
10. Cap the opening on the fuel tank in order the prevent possible fuel system contamination.

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel fill pipe to the vehicle and 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. Tighten the fuel tank fill pipe clamp.

Tighten
Tighten the clamp to 2.5 N·m (22 lb in).




4. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.



5. Install the chassis harness ground strap (2) and fuel tank ground strap (4).
6. Install the fuel tank ground strap bolt (3).

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 screws.

Tighten
Tighten the screws to 2.3 N·m (20 lb in).




10. Install the fuel tank filler housing to body screws (1), and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (20 lb in).

Filler Tube Replacement Cab/Chassis

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Disconnect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .



3. Loosen the fuel fill and vent hose clamps at the tank.
4. Remove the fuel fill pipe and vent hose from the tank.
5. Cap the fuel and vent holes in the fuel tank in order to prevent possible fuel system contamination.

1. Remove the caps from the fuel and vent holes in the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the fuel fill pipe and vent hose to the tank.
3. Tighten the fuel fill and vent hose clamps at the tank.

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




4. Connect the fuel feed and pressure balance rear pipes. Refer to Metal Collar Quick Connect Fitting Service .