Filler Tube Replacement Single Tank

Important: Clean all fuel pipe and hose connections and surrounding areas before disconnection in order to avoid possible contamination of the fuel system.

1. Remove the fuel fill cap.



2. Remove the spare tire stowage lock cylinder.



3. Remove the spare tire.



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



6. Open the rear axle vent hose clip (3) at the fill pipe and remove the vent hose.



7. Remove the fuel fill pipe ground strap bolt (2).
8. Loosen the fuel fill pipe vent hose to fuel tank clamp.
9. Loosen the fuel fill pipe to fuel tank clamp.
10. Remove the fuel fill pipe bracket bolt (1).
11. Separate the fuel fill pipe and vent hose from the fuel tank.
12. Disengage the fuel fill pipe bracket from the frame.
13. Remove the fuel fill pipe and vent hose.
14. Cap the open end of the fuel tank to prevent system contamination.

1. Uncap the fuel tank opening.
2. Install the fuel fill pipe and vent hose 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. Engage the fuel fill pipe bracket to the frame.
4. Install the fuel fill pipe bracket bolt (1).

Tighten
Tighten the bolt to 12 N·m (106 lb in).

5. Tighten the fuel fill pipe vent hose to fuel tank clamps.

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

6. Install the fuel fill pipe ground strap bolt (2).

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




7. Install the rear axle vent hose clip (3) at the fill pipe.
8. Lower the vehicle.



9. Remove 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 spare tire.



11. Install the spare tire stowage lock cylinder.



12. Install the fuel fill cap.

Filler Tube Replacement Dual Tanks

1. Remove the fuel fill cap.



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



4. Remove the fuel pipe ground strap bolt.
5. Separate the ground straps (1, 2).



6. Remove the rear axle vent hose from the retaining clip (2).



7. Loosen the fuel tank fill pipe clamp at the rear tank.
8. Loosen the vent hose clamp at the rear tank.
9. Separate the fill pipe from the rear tank.
10. Separate the vent hose from the rear tank.
11. Remove the fuel fill pipe.
12. Cap the open end of the fuel tank to prevent system contamination.

1. Uncap the fuel tank.
2. Install the fuel fill pipe.
3. Connect the vent hose to the rear tank.
4. Connect the fill pipe to the rear tank.
5. Tighten the vent hose clamp at the rear 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.

6. Tighten the fuel tank fill pipe clamp at the rear tank.

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




7. Install the rear axle vent hose to the retaining clip (2).



8. Position the ground straps (1, 2).
9. Install the fuel pipe ground strap bolt.

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

10. Lower the vehicle.



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

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




13. If necessary, fill the fuel tank.
14. Install the fuel fill cap.