Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tank)

Fuel Tank Filler Pipe Replacement (15/25 Reg/Ext/Crw Cab With 34 Gal Tnk)

Removal Procedure




1. Remove the fuel tank filler housing to body TORX(R) 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 (Service and Repair).




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. 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 (Plastic Collar Quick Connect Fitting Service).
10. Remove the fuel tank fill pipe.
11. 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.
3. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
Caution: Refer to Fastener Caution (Fastener Caution).

4. Tighten the fuel tank fill pipe clamp (2) at the fuel tank.

Tighten the clamp to 2.5 Nm (22 lb in).




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

Tighten the bolt to 9 Nm (80 lb in).




8. Lower the vehicle.
9. Install the fuel tank filler housing.
10. Install the fuel tank filler housing to fuel tank fill pipe bolts.

Tighten the bolts to 2.3 Nm (20 lb in).




11. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2).

Tighten the screws to 2.3 Nm (20 lb in).