Fuel Tank Filler Pipe Replacement (1500 Series)
Fuel Tank Filler Pipe Replacement (1500 Series)
Removal Procedure
Note:
Clean the fuel connections and surrounding areas prior to disconnecting the lines in order to avoid possible contamination.
1. Remove the fuel fill cap.
2. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2).
3. Remove the spare tire stowage lock cylinder, if necessary.
4. Remove the spare tire, if necessary.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
6. Remove the rear axle vent hose clip (1) from the fill pipe.
7. If necessary, remove the air suspension hose at the fill pipe.
8. Remove the chassis wiring harness ground bolt (2).
9. Remove the left rear lamp ground wire (4) and fill pipe ground strap (5) from the frame.
10. Disconnect the fuel tank vent line quick connect fitting (5) from the fill pipe line. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
11. Disconnect the fuel fill hose vent line quick connect fitting (3) from the EVAP canister vent solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
12. Loosen the fuel fill hose clamp (6).
13. Remove the fuel fill pipe bracket bolts (2, 4).
14. Remove the fuel fill hose from the fuel tank.
15. Cap the fuel tank opening and EVAP vent line in order to prevent fuel/EVAP system contamination.
16. If replacing any serviceable part of the fill pipe assembly proceed to the disassemble procedure, otherwise proceed to the installation procedure.
Disassemble Procedure
* Fuel tank filler vent hose (1)
* Fuel tank fill pipe housing bolts (2)
* Fuel tank fill pipe housing (3)
* Fuel tank fill hose (4)
* Fuel tank fill pipe clip (5)
* Fuel tank fill hose clamp (6)
* Fuel tank fill hose (7)
* Fuel tank fill hose clamp (8)
* Evaporative emission hose (9)
* Evaporative emission hose clamp (10)
Assemble Procedure
Caution:
Refer to Fastener Caution Fastener Caution.
* Evaporative emission hose clamp (10)
Tighten the clamp to 2.5 Nm (22 lb in).
* Evaporative emission hose (9)
* Fuel tank fill hose clamp (8)
Tighten the clamp to 2.5 Nm (22 lb in).
* Fuel tank fill hose (7)
* Fuel tank fill hose clamp (6)
Tighten the clamp to 2.5 Nm (22 lb in).
* Fuel tank fill pipe clip (5)
* Fuel tank fill hose (4)
* Fuel tank fill pipe housing (3)
* Fuel tank fill pipe housing bolts (2)
Tighten the bolts to 2.3 Nm (20 lb in).
* Fuel tank filler vent hose (1)
Installation Procedure
1. Remove the caps from the fuel tank opening and the EVAP vent line.
2. Install the fuel fill hose to the fuel tank. Ensure that the notch in the hose is aligned with the notch on the fuel tank.
3. Tighten the fuel fill hose clamp (6).
Tighten the clamps to 2.5 Nm (22 lb in).
4. Install the fuel fill pipe bracket bolts (2, 4).
Tighten the bolt to 12 Nm (106 lb in).
5. Connect the fuel fill hose vent line quick connect fitting (3) to the EVAP canister vent solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service Procedures.
6. Connect the fuel fill pipe vent line to the fuel tank quick connect fitting (5). Refer to Plastic Collar Quick Connect Fitting Service Procedures.
7. Position the fill pipe ground strap (5) to the left rear lamp ground wire (4).
8. Install the rear lamp ground wire (4) and ground strap (5) to the frame. Insert the lamp ground wire anti-rotation tab into the hole in the frame.
9. Install the chassis wiring harness ground bolt.
Tighten the bolt to 9 Nm (80 lb in).
10. If necessary, install the air suspension hose at the fill pipe.
11. Install the rear axle vent hose clip (1) to the fill pipe.
12. Lower the vehicle.
13. 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).
14. Install the spare tire, if necessary.
15. Install the spare tire stowage lock cylinder, if necessary.
16. Install the fuel fill cap.