Fuel Tank Filler Pipe Replacement

Engine Controls and Fuel - 5.3L L84 or 6.2L L87 | Repair Instructions | Document ID: 5550613 Single Use Fasteners and Components Tie Strap [4x] Fuel Tank Filler Pipe Housing

Warning

Refer to Diesel/Gasoline Vapors Warning.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Drain the fuel tank just below the fuel tank filler hose. Fuel Tank Draining

Fuel Tank Filler Pipe Replacement — figure 1

2. Fuel Tank Filler Door (1) » Release the retainers.

Fuel Tank Filler Pipe Replacement — figure 2

Note

Work the rubber seal around filler pipe prior to fuel tank filler pipe housing removal.

3. Fuel Tank Filler Pipe Housing Retainer (1) » Release [4x]

Note

The fuel tank filler pipe housing once removed can NOT be reused and must be replaced with a NEW fuel tank filler pipe housing.

4. Fuel Tank Filler Pipe Housing (2) » Remove and DISCARD

Fuel Tank Filler Pipe Replacement — figure 3

5. Fuel Tank Filler Pipe Ground Bolt (1) » Remove [3x]
6. Remove the spare tire.

Fuel Tank Filler Pipe Replacement — figure 4

7. Raise and support the vehicle. Lifting and Jacking the Vehicle
8. Spare Wheel Heat Shield Bolt (2) » Remove [3x]
9. Spare Wheel Heat Shield (1) » Remove

Fuel Tank Filler Pipe Replacement — figure 5

10. Tie Strap (2) » Remove and DISCARD
11. Rear Axle Vent Hose (3) » Remove
12. Retainer (4) @ Evaporative Emission Canister Vent Hose (3) » Remove

Fuel Tank Filler Pipe Replacement — figure 6

13. Fuel Tank Filler Pipe Bracket Bolt (1) » Remove
14. Tie Strap (2) » Remove and DISCARD

Fuel Tank Filler Pipe Replacement — figure 7

15. Tie Strap (1) » Remove and DISCARD
16. Fuel Tank Filler Vent Hose (2) Disconnect — Plastic Collar Quick Connect Fitting Service
17. Fuel Tank Filler Hose Clamp (3) » Loosen

Fuel Tank Filler Pipe Replacement — figure 8

18. Fuel Tank Filler Pipe Bracket Bolt (1) » Remove

Fuel Tank Filler Pipe Replacement — figure 9

19. Remove the 2 rear axle vent hose retainers.

20. Fuel Tank Filler Pipe (1) » Remove Installation Procedure

21. Fuel Tank Filler Pipe (1) » Install

22. Install the 2 rear axle vent hose retainers.

Caution

Refer to Fastener Caution.

3. Fuel Tank Filler Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

4. Fuel Tank Filler Hose Clamp (3) » Tighten — Fastener Specifications

5. Fuel Tank Filler Vent Hose (2) Connect — Plastic Collar Quick Connect Fitting Service

6. Tie Strap (1) » Install NEW

7. Tie Strap (2) » Install NEW

8. Fuel Tank Filler Pipe Bracket Bolt (1) » Install and tighten — Fastener Specifications

9. Retainer (4) @ Evaporative Emission Canister Vent Hose » Install

10. Rear Axle Vent Hose (3) » Install

11. Tie Strap (2) » Install NEW

12. Spare Wheel Heat Shield (1) » Install

13. Spare Wheel Heat Shield Bolt (2) » Install and tighten [3x] — Fastener Specifications

14. Lower the vehicle.

15. Install the spare tire.

16. Fuel Tank Filler Pipe Ground Bolt (1) » Install and tighten [3x] — Fastener Specifications

17. Fuel Tank Filler Pipe Housing (2) » Install NEW

18. Fuel Tank Filler Pipe Housing Retainer (1) » Secure the retaining tabs. [4x]

19. Fuel Tank Filler Door (1) » Install

20. Refill the fuel tank.