Remove Fuel Fill Neck

FUEL FILL NECK REMOVAL

NOTE: Whenever the fuel fill neck requires removal, the fuel level should not be more than 3/4 full. If more than 3/4 full, use extreme care when disconnecting hoses and removing tank.

1. Position vehicle on hoist.
2. Disconnect negative battery cable battery.

Fuel Neck Installation:

3. Open fuel door and remove upper neck fasteners and fuel cap at left-hand side rear quarter panel.

WARNING: Make sure vehicle is properly supported and squarely possidendi. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.

4. Raise vehicle to a comfortable working position.

WARNING: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.

WARNING: any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.

5. Raise rear of vehicle approximately 28 inches to a comfortable working position. This allows the fuel to flow forward in the tank away from the fill hose opening.
6. Remove fill neck bracket fastener at left-hand side rear frame rail.

WARNING: Never drain or store fuel in an open container due to the possibility of fire or explosion.

WARNING: Whenever fuel tank fill neck hose is removed, catch fuel in an approved container. container opening must be a minimum of 300 mm (12 in.) diameter to adequately catch the fluid.

Fuel Tank Fill And Vent Hoses:

7. Position an approved drain container with enough capacity to hold the fuel under the fill neck. Loosen the fuel filler neck connecting tube clamp at rear of tank. Wrap a shop towel around fuel filler neck connecting tube and slowly remove fuel filler neck connecting tube from fuel tank.
8. Loosen fill and vent hose clamps at tank.
9. Remove fill neck from vehicle.


INSTALLATION

Fuel Neck Installation:

1. Install fill neck and loosely attach fill and vent hoses.

NOTE: To prevent driver's side quarter panel deflection, care must be taken when installing fuel fill neck and tank to insure they are properly aligned.

2. Finger start fill neck-to-frame rail fastener.
3. Install upper fill neck fasteners.
Torque to 2 N.m (18 in-lbs)

4. Tighten fill neck bracket-to-frame rail fastener.
Torque to 6 N.m (53 in-lbs)

5. Install fill neck and vent hose clamps.
Torque to 3 N.m (27 in-lbs)

6. Fill vehicle with fuel and install fill cap.
7. Run engine and check fuel system for leaks.