Fuel Tank Filler Pipe
Fuel Tank Filler Pipe
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.
WARNING: 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.
WARNING: 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.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. Remove the LH rear wheel and tire.
4. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
5. NOTICE: When removing the Fuel Draining Hose, the fitting on the end of the hose can become detained by the safety valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.
NOTE: The Fuel Draining Hose must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank, opening the safety valve.
Insert the Fuel Draining Hose into the fuel tank filler pipe.
6. NOTE: This step will remove approximately one-eighth tank of fuel from a completely full fuel tank and the majority of any residual fuel from the fuel tank filler pipe. Also the fuel in the fuel tank will be below the fuel tank inlet or fuel tank filler pipe removal without fuel spillage.
Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove approximately one-eighth tank of fuel (from a completely full tank), lowering the fuel below the fuel tank inlet.
7. Release the 4 clips and remove the fuel tank filler pipe upper retainer.
8. 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).
9. Disconnect the fuel vapor tube assembly-to-fuel tank filler pipe recirculation tube spring lock coupling.
10. Remove the fuel tank filler pipe bracket bolt.
- To install, tighten to 25 Nm (18 lb-ft).
11. Loosen the lateral stiffener bar-to-body mount nut.
- To install, tighten to 115 Nm (85 lb-ft).
12. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser qualify or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
NOTE: Make sure to install new lateral stiffener bar-to-body bolts.
Remove and discard the 2 lateral stiffener bar-to-body bolts and position the bar aside.
- To install, tighten to 62 Nm (46 lb-ft).
4.6L and 5.4L vehicles
13. Remove the LH exhaust intermediate pipe.
All vehicles
14. Remove the fuel tank filler pipe.
15. To install, reverse the removal procedure.