Dual Tanks
REMOVAL PROCEDURECAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.
Fuel Filler Cap:
1. Disconnect the negative battery cable.
2. Clean all the fuel pipe and hose connections and the surrounding areas before disconnection in order to avoid possible contamination of the fuel system.
3. Remove the fuel filler cap.
4. Drain the fuel below the level of the fuel filler hose. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
5. Remove the fuel fill pipe housing to fuel fill pipe bolts.
6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Disconnect the fuel fill pipe ground strap.
8. Disconnect the rear axle vent hose from the retainer on the fuel fill pipe.
9. Loosen the fuel vent hose (3) to fill tube clamp (2).
10. Loosen the fuel fill hose to fuel tank clamp (2).
11. Disconnect the fuel fill hose from the fuel tank.
12. Remove the fuel fill hose assembly.
13. Cap the open end of the fuel tank.
INSTALLATION PROCEDURE
1. Uncap the fuel tank.
NOTE: Refer to Fastener Notice in Cautions and Notices.
2. Install the fuel fill hose assembly to the fuel tank.
Tighten
Tighten the fuel fill pipe clamp (2), to 2.5 N.m (22 lb in)
3. Connect the fuel fill vent hose (3) to the fill tube.
Tighten
Tighten the vent hose clamp (2), to 2.5 N.m (22 lb in)
4. Connect the fuel fill pipe ground strap.
Tighten
Tighten the fuel fill pipe ground strap bolt to 9 N.m (80 lb in)
5. Connect the rear axle vent hose to the retainer on the fuel fill pipe.
6. Lower the vehicle.
7. Install the fuel fill pipe housing to the fuel fill pipe bolts.
Tighten
Tighten the fuel fill pipe housing to fuel fill pipe bolts to 2.3 N.m (20 lb in)
Fuel Filler Cap:
8. Refill the fuel system.
9. Install the fuel filler cap.
10. Connect the negative battery cable.