Fuel Tank Filler Pipe Replacement 1500 Series

Important: 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® 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 .



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 .
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 .
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.

•	Fuel tank filler vent hose (1)

•	Notice: Refer to Fastener Notice in the Preface section. Evaporative emission hose clamp (10) Tighten Tighten the clamp to 2.5 N·m (22 lb in).

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

4. Install the fuel fill pipe bracket bolts (2, 4).

Tighten
Tighten the bolt to 12 N·m (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 .
6. Connect the fuel fill pipe vent line to the fuel tank quick connect fitting (5). Refer to Plastic Collar Quick Connect Fitting Service .



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
Tighten the bolt to 9 N·m (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® screws (1) and retainer (2).

Tighten
Tighten the screws to 2.3 N·m (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.

Fuel Tank Filler Pipe Replacement 2500 Series

1. Remove the rear fuel tank. Refer to Fuel Tank Replacement .
2. Remove the chassis wiring harness ground bolt (2).
3. Remove the left rear lamp ground wire (4) and fill pipe ground strap (5) from the frame.



4. Remove the rear axle vent hose clip from the fill pipe neck.
5. Loosen the fuel tank fill hose clamp (1) at the front tank.
6. Disconnect the fuel fill hose evaporative emission (EVAP) line quick connect fitting (2) from the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service .
7. Remove the fuel fill hose from the front tank.
8. Remove the fuel fill hose integral clamp from the crossmember.
9. Remove the fuel fill hose/pipe assembly.
10. Cap the open end of the fuel tank in order to prevent fuel system contamination.
11. Cap the open ends of the fuel/EVAP lines in order to prevent fuel/EVAP system contamination.
12. If replacing any serviceable part of the fill pipe assembly proceed to the disassemble procedure, otherwise proceed to the installation procedure.

•	Evaporative emission canister hose (1)

•	Notice: Refer to Fastener Notice in the Preface section. Fuel tank fill hose clamp (12) Tighten Tighten the clamp to 2.5 N·m (22 lb in).

1. Remove the caps from the open end of the front fuel tank.
2. Remove the caps from the fuel/EVAP lines.
3. Install the fuel fill hose/pipe assembly.
4. Install the fuel fill hose to the front tank.
5. Connect the fuel fill hose EVAP line quick connect fitting (2) to the fuel tank line. Refer to Plastic Collar Quick Connect Fitting Service .
6. Tighten the fuel tank fill hose clamp (1) at the front tank.

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

7. Install the fuel fill hose integral clamp to the crossmember.
8. Install the rear axle vent hose clip to the fill pipe neck.



9. Position the fill pipe ground strap (5) to the left rear lamp ground wire (4).
10. 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.
11. Insert the chassis wiring harness ground bolt.

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

12. Install the rear fuel tank. Refer to Fuel Tank Replacement .