Filler Tube Replacement Pickup

Removal Procedure

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 .



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 Plastic Collar Quick Connect Fitting Service .
12. Remove the fuel tank fill pipe.
13. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel tank fill pipe.

Notice: Refer to Fastener Notice in the Preface section.

3. Connect the recirculation line to the sending unit. Refer to Plastic Collar Quick Connect Fitting Service .
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).

Filler Tube Replacement Cab/Chassis - Front

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. If equipped with a rear auxiliary tank, disconnect the fuel and evaporative emission (EVAP) quick connect fittings. Refer to Metal Collar Quick Connect Fitting Service .
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.

Installation Procedure

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

Notice: Refer to Fastener Notice in the Preface section.

2. Install the fuel fill pipe and vent pipe to the tank.
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 Metal Collar Quick Connect Fitting Service .

Filler Tube Replacement Cab/Chassis - Rear

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
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.

Installation Procedure

1. Install the fuel fill and vent hoses to the tank.

Notice: Refer to Fastener Notice in the Preface section.

2. Tighten the fuel vent pipe hose clamp (1) at the tank.
3. Tighten the fuel fill pipe hose clamp (2) at the tank.

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

Filler Tube Replacement 1500 Crew Cab

Removal Procedure

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 .



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 Plastic Collar Quick Connect Fitting Service .
9. Remove the fuel tank fill pipe.
10. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel tank fill pipe.

Notice: Refer to Fastener Notice in the Preface section.

3. Connect the recirculation line quick connect fitting at the tank. Refer to Plastic Collar Quick Connect Fitting Service .
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).