Filler Tube Replacement Regular Cab w/26 Gal Tank

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 (3).
6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1).



8. Open the axle vent hose clip on the fuel fill pipe bracket.
9. Remove the rear axle vent hose from the clip.



10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. Refer to Plastic Collar Quick Connect Fitting Service .
11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
12. Remove the fuel tank fill pipe.
13. Cap the opening on the fuel tank in order to prevent possible system contamination.

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

Notice: Refer to Fastener Notice in the Preface section.

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

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

4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. Refer to Plastic Collar Quick Connect Fitting Service .



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 chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
9. Install the fuel tank fill pipe ground wire bolt (3).

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 Extended Cab w/26 Gal Tank

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.
6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole.
7. Reposition the fuel tank fill pipe ground wire.



8. Open the axle vent hose clip on the fuel fill pipe bracket.
9. Remove the rear axle vent hose from the clip.



10. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
12. Remove the fuel tank fill pipe.
13. Cap the opening on the fuel tank in order to prevent possible system contamination.

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

Notice: Refer to Fastener Notice in the Preface section.

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

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

4. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service .



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 to the frame bracket.
8. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole.
9. Install the fuel tank fill pipe ground wire bolt.

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 Regular Cab w/34 Gal Tank

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 screws.
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 (3).
6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole.
7. Reposition the fuel tank fill pipe ground wire and the chassis harness ground wire (1), if equipped.



8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
10. Disconnect the vent tube attached at upper filler neck.
11. Remove the fuel tank fill pipe.
12. Cap the opening on the fuel tank in order to prevent possible system contamination.

1. Remove the cap from the opening on the fuel tank.
2. Install the fuel tank fill pipe.
3. Connect the vent tube to the upper filler neck.

Notice: Refer to Fastener Notice in the Preface section.

4. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
5. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

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




6. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket.
7. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole.
8. Install the fuel tank fill pipe ground wire bolt (3).

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 bolts.

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




12. 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).