Fuel Filler Hose: Service and Repair

FUEL TANK FILLER PIPE

Exploded View

Part 1:

Part 2:

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.
- Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.

All vehicles
1. Remove the LH rear wheel and tire.
2. Release the fuel tank filler cap and position aside.

3. NOTE:
- When the fuel tank is completely full, this step will remove approximately 1/8 of the fuel from the fuel tank.
- The special tool must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank inlet, opening the safety valve allowing fuel tank drainage. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.

Insert the special tool into the fuel tank filler pipe.
- Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel tank inlet.







4. Release the 4 clips and remove the fuel tank filler pipe upper retainer.

5. NOTE: Some fuel may remain in the fuel tank filler pipe after draining. Carefully disconnect the fuel tank filler pipe hose from the fuel tank and drain any residual fuel into a suitable container.

Release the clamp and disconnect the fuel tank filler pipe-to-fuel tank hose.
- To install, tighten to 6 Nm (53 lb-in).

6. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube spring lock coupling.

7. Remove the fuel tank filler pipe bracket bolt.
- To install, tighten to 25 Nm (18 lb-ft).

8. Loosen the lateral stiffener bar-to-body mount nut.
- To install, tighten to 115 Nm (85 lb-ft).

9. Remove and discard the lateral stiffener bar-to-body bolts.
- Position the lateral stiffener bar aside.
- To install, tighten to 62 Nm (46 lb-ft).

4.6L and 5.4L vehicles
10. Remove the LH exhaust intermediate pipe.

All vehicles
11. Remove the fuel tank filler pipe.
12. To install, reverse the removal procedure.