Fuel Filler Hose: Service and Repair
FUEL TANK FILLER PIPEExploded View
Part 1:
Part 2:
Special Tool(s)
Special Tool(s):
Removal and Installation
WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
- Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury.
1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.
With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel tank filler cap and position aside.
3. NOTE: The fuel tank filler pipe has an internally mounted spark arrestor that will not allow a drain tube to enter into the fuel tank.
Insert the tube from the special tool into the fuel tank filler pipe as far as possible and drain any residual fuel that may remain in the pipe.
4. Remove the 4 fuel tank filler pipe flange bolts.
- To install, tighten to 5 Nm (44 lb-in).
5. Remove the 4 fuel tank filler pipe seal bolts.
- To install, tighten to 5 Nm (44 lb-in).
6. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube quick connect coupling.
7. Remove the fuel tank filler pipe bracket bolt.
- To install, tighten to 5 Nm (44 lb-in).
8. Position a suitable lifting device under the fuel tank.
9. NOTE: Discard old retaining nuts. Do not reuse.
Remove the 2 nuts and the fuel tank straps.
- To install, tighten to 35 Nm (26 lb-ft).
10. Partially lower the fuel tank to allow fuel tank filler pipe removal.
11. Remove the fuel tank filler pipe assembly.
- Rotate the fuel tank filler pipe counterclockwise 1/2 turn and remove from the fuel tank.
12. NOTE: The fuel tank strap studs are manufactured as a break-off style. After installing the new fuel tank strap studs and fuel tank installation is completed, break-off the excess length at the recess in the studs.
Remove and discard the fuel tank strap studs.
13. To install, reverse the removal procedure.
- Apply clean engine oil to the fuel tank filler pipe and grommet prior to installation.
14. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.
If equipped with fire suppression system, repower the system.