Fuel Tank Filler Pipe Replacement
Single Use Fasteners and Components

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

    2. Object ID: 5582306
  2. Position the fuel tank filler door (1) to the fill open position.
  3. Remove the emission reduction fluid tank filler pipe cap.
  4. Using the appropriate tool, release the filler door retainers and remove the fuel tank filler door (1).

    5. Object ID: 5582308

    Note: The fuel tank filler pipe housing once removed cannot be reused and must be replaced with a NEW fuel tank filler pipe housing.

  5. Using a flat-bladed tool that fits into the 4 depressions (1) , break through the 4 depressions with light pressure and then pry the clips free to release the fuel tank filler pipe housing from the body side outer panel.
  6. Fuel Tank Filler Pipe Housing(2)»Remove and DISCARD

    7. Object ID: 5617633
  7. Fuel Tank Filler Pipe Housing Bolt(1)»Remove[3x]
  8. Raise and support the vehicle.Lifting and Jacking the Vehicle

    9. Object ID: 5617636
  9. Retainer(1)»Remove

    10. Object ID: 5808255
  10. Reposition the fuel tank filler and emission reduction fluid tank filler pipe assembly (1) to gain access to bolts.
  11. Emission Reduction Fluid Tank Filler Upper Pipe Bolt (2)»Remove[3x]
  12. Emission Reduction Fluid Tank Filler Pipe(3)»Remove
  13. Emission Reduction Fluid Tank Filler Pipe(3)»Reposition

    14. Object ID: 5617642
  14. Fuel Tank Filler Pipe Bracket Bolt(1)»Remove
  15. Retainer(2)»Remove

    16. Object ID: 5617643
  16. Fuel Tank Filler Pipe Bracket Bolt(1)»Remove
  17. Retainer(2)»Remove
  18. Fuel Tank Filler Vent Hose(3)»Disconnect—Plastic Collar Quick Connect Fitting Service
  19. Fuel Tank Filler Hose Clamp(4)»Loosen
  20. Fuel Tank Filler Hose(5)»Remove

    21. Object ID: 5671098
  21. Fuel Tank Filler Pipe(1)»Remove

Installation Procedure


    Object ID: 5671098
  1. Fuel Tank Filler Pipe(1)»Install

    2. Object ID: 5617643
  2. Fuel Tank Filler Hose(5)»Install

    3. Caution: Refer to Fastener Caution.

  3. Fuel Tank Filler Hose Clamp(4)»Tighten—Fastener Specifications
  4. Fuel Tank Filler Vent Hose(3)»Connect—Plastic Collar Quick Connect Fitting Service
  5. Retainer(2)»Install
  6. Fuel Tank Filler Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications

    7. Object ID: 5617642
  7. Retainer(2)»Install
  8. Fuel Tank Filler Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications

    9. Object ID: 5617636
  9. Retainer(1)»Install
  10. Lower the vehicle.

    11. Object ID: 5808255
  11. Reposition the emission reduction fluid tank filler pipe (3) back into place.
  12. Emission Reduction Fluid Tank Filler Pipe(3)»Install
  13. Reposition the fuel tank filler and emission reduction fluid tank filler pipe assembly (1) to gain access to bolts.
  14. Emission Reduction Fluid Tank Filler Upper Pipe Bolt (2)»Install and tighten[3x]—Fastener Specifications

    15. Object ID: 5617633
  15. Fuel Tank Filler Pipe Housing Bolt(1)»Install and tighten[3x]—Fastener Specifications

    16. Object ID: 5582308
  16. Fuel Tank Filler Pipe Housing(2)»Install NEW
  17. Press the fuel tank filler pipe housing  depressions (1) to the body side outer panel until fully seated.
  18. Ensure the fuel tank filler pipe housing seal is full seated to the filler pipe.
  19. Install the emission reduction fluid tank filler pipe cap.

    20. Object ID: 5582306

    Note: When replacing the fuel tank filler pipe housing or door, always install NEW fuel labels to the component that was replaced.

  20. Fuel Tank Filler Door(1)»Install
  21. Refill the fuel tank.