Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/26 gal Tank)

Fuel Tank Filler Pipe Replacement (15 Ext/Crew Cab w/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 Vehicle Lifting.




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. If equipped with 5 ft 8 in. bed, perform the following steps:
11. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line.
12. Loosen the fuel tank fill pipe clamp (1) at the fuel tank.
13. Remove the fuel tank fill pipe.
14. Cap the opening on the fuel tank in order to prevent possible system contamination.




15. If equipped with 6 ft 5 in. bed, perform the following steps:
16. Disconnect the fuel tank EVAP line quick connect fitting (1) from the fuel fill pipe recirculation line.
17. Loosen the fuel tank fill pipe clamp (2) at the fuel tank.
18. Remove the fuel tank fill pipe.
19. Cap the opening on the fuel tank in order to prevent possible system contamination.

Installation Procedure




1. If equipped with 6 ft 5 in. bed, perform the following steps:
2. Remove the cap from the opening on the fuel tank.
3. Position the fuel tank fill pipe.

Notice: Refer to Fastener Notice.

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

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

5. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (1).




6. If equipped with 5 ft 8 in. bed, perform the following steps:
7. Remove the cap from the opening on the fuel tank.
8. Position the fuel tank fill pipe.
9. Tighten the fuel tank fill pipe clamp (1) at the fuel tank.

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

10. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2).




11. Install the rear axle vent hose to the clip on the fuel fill pipe bracket.
12. Close the axle vent hose clip.




13. Position the fuel tank fill pipe ground wire to the frame bracket.
14. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole.
15. Install the fuel tank fill pipe ground wire bolt.

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

16. Lower the vehicle.




17. Install the fuel tank filler housing.
18. Install the fuel tank filler housing to fuel tank fill pipe bolts.

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




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

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