Filler Tube Replacement Single Tank

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. If necessary, remove the spare tire stowage lock cylinder.



4. If necessary, remove the spare tire.



5. Remove the fuel tank filler housing to fuel tank fill pipe screws.
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



7. Open the rear axle vent hose clip at the fill pipe and remove the vent hose (2).
8. If necessary, remove the air suspension hose at the fill pipe.



9. Remove the ground wire harness bolt.
10. Remove the ground wire and fill pipe ground strap.



11. Disconnect the vent hose quick connect fitting at the fuel tank. Refer to Plastic Collar Quick Connect Fitting Service .
12. Loosen the fuel fill pipe clamp (1).
13. Remove the fuel fill pipe bracket bolts (2).
14. Separate the fuel fill pipe hose from the fuel tank.
15. Remove the fuel fill pipe and vent hose.
16. Cap the open end of the fuel tank to prevent system contamination.

1. Uncap the fuel tank opening.
2. Install the fuel fill pipe hose to the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the fuel fill pipe bracket bolts (2).

Tighten
Tighten the bolt to 12 N·m (106 lb in).

4. Tighten the fuel fill pipe hose clamp (1).

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

5. Connect the vent hose quick connect fitting to the tank. Refer to Plastic Collar Quick Connect Fitting Service .



6. Position the fill pipe ground strap and ground wire.
7. Install the ground wire harness bolt.

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




8. If necessary, install the air suspension hose at the fill pipe.
9. Install the vent hose (2) to the clip and close the clip at the fill pipe.
10. Lower the vehicle.



11. Install the fuel tank filler housing to fuel tank fill pipe screws.

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




12. 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).




13. If necessary, install the spare tire.



14. If necessary, install the spare tire stowage lock cylinder.



15. Install the fuel tank filler housing to body TORX® screws (1) and retainer (2).



16. Install the fuel fill cap.

Filler Tube Replacement Dual Tanks - 6.0L Engine

1. Remove the rear fuel tank. Refer to Fuel Tank Replacement .
2. Remove the ground wire harness bolt.
3. Reposition the ground wire and fill pipe ground strap.



4. Open the rear axle vent hose clip at the fill pipe and remove the vent hose.



5. Loosen the fuel tank fill hose clamp at the front tank.
6. Disconnect the fuel fill hose vent line quick connect fitting from the tank. Refer to Plastic Collar Quick Connect Fitting Service .
7. Remove the fill hose from the front tank.
8. Remove the fuel fill hose/pipe assembly.
9. Cap the open end of the fuel tank to prevent system contamination.

1. Remove the cap from the open end of the front fuel tank.
2. Install the fuel fill hose/pipe assembly.
3. Install the fill hose to the front tank.

Notice: Refer to Fastener Notice in the Preface section.

4. Connect the fuel fill hose vent line quick connect fitting to the tank. Refer to Plastic Collar Quick Connect Fitting Service .
5. Tighten the fuel tank fill hose clamp at the front tank.

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




6. Install the rear axle vent hose to the retaining clip and close the clip.



7. Position the ground wire and fill pipe ground strap.
8. Install the ground wire harness bolt.

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

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

Filler Tube Replacement Single Tank - 5.3L (L59) Engine

Important: Clean all fuel pipe and hose connections and surrounding areas before disconnection in order to avoid possible contamination of the fuel system.

1. Remove the fuel fill cap.



2. Remove the spare tire stowage lock cylinder.



3. Remove the spare tire.



4. Remove the fuel tank filler housing to fuel tank fill pipe screws.
5. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



6. Open the rear axle vent hose clip (3) at the fill pipe and remove the vent hose.



7. Remove the fuel fill pipe ground strap bolt (2).
8. Loosen the fuel fill pipe vent hose to fuel tank clamp.
9. Loosen the fuel fill pipe to fuel tank clamp.
10. Remove the fuel fill pipe bracket bolt (1).
11. Separate the fuel fill pipe and vent hose from the fuel tank.
12. Disengage the fuel fill pipe bracket from the frame.
13. Remove the fuel fill pipe and vent hose.
14. Cap the open end of the fuel tank to prevent system contamination.

1. Uncap the fuel tank opening.
2. Install the fuel fill pipe and vent hose to the fuel tank.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Engage the fuel fill pipe bracket to the frame.
4. Install the fuel fill pipe bracket bolt (1).

Tighten
Tighten the bolt to 12 N·m (106 lb in).

5. Tighten the fuel fill pipe vent hose to fuel tank clamps.

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

6. Install the fuel fill pipe ground strap bolt (2).

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




7. Install the rear axle vent hose clip (3) at the fill pipe.
8. Lower the vehicle.



9. Remove the fuel tank filler housing to fuel tank fill pipe screws.

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




10. Install the spare tire.



11. Install the spare tire stowage lock cylinder.



12. Install the fuel fill cap.