Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank)

Fuel Tank Filler Pipe Replacement (25 Ext/Crew Cab With 26 Gal Tank)

Removal Procedure




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

Installation Procedure




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

Caution: Refer to Fastener Caution (Fastener Caution).

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

Tighten the clamp to 2.5 Nm (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 (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 the bolt to 9 Nm (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 the screws to 2.3 Nm (20 lb in).




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

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