Fuel Tank Filler Hose Replacement Pickup

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



2. Remove the fuel tank filler pipe 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.



5. Remove the fuel tank ground strap bolt (1).
6. Remove the chassis harness ground strap (2) and fuel tank ground strap (3).



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



8. Loosen the fuel tank vent hose and fill hose clamps (1, 2).
9. Remove the vent hose from the tank.
10. Remove the fill hose from the tank and the vehicle.
11. Cap the opening on the fuel tank in order to prevent possible fuel system contamination.

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

Caution: Refer to Fastener Caution in the Preface section.

3. Install the vent hose to the tank.
4. Tighten the fuel tank vent hose and fill hose clamps (1, 2).

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. Position the chassis harness ground strap (2) and fuel tank ground strap (3).
7. Install the ground strap anti-rotation tab into the frame hole.
8. Install the fuel tank ground strap bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).

9. Lower the vehicle.



10. Install the fuel tank filler housing.
11. Install the fuel tank filler housing to fuel tank fill pipe screws.

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




12. 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).

Fuel Tank Filler Hose Replacement Cab/Chassis

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



3. Loosen the fuel fill and vent hose clamps (1, 2) at the tank.
4. Remove the fuel fill and vent hoses 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.

Caution: Refer to Fastener Caution in the Preface section.

2. Install the fuel fill and vent hoses to the tank.
3. Tighten the fuel fill and vent hose clamps (1, 2) at the tank.

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




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