Fuel Filler Neck: Service and Repair

Fuel Tank Filler Pipe

Service Repair No - 19.55.07

Removal

WARNING:
^ After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow this instruction may result in personal injury.
^ After the fuel tank drain is complete always fit the sealing covers over the drain ports. failure to do so will mean that fuel vapor can escape.
^ This procedure involves fuel handling. be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
^ Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. should irritation develop, seek medical attention.
^ Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

CAUTION:
^ Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.
^ Make sure the workshop area in which the vehicle is being worked on is as clean and as dust free as possible. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel system and may result in later malfunction.

1. Position the vehicle on a lift.
2. Disconnect the battery ground cable.
3. Drain the fuel tank.
4. Remove the rear driveshaft.
5. Remove the RH rear fender splash shield.
6. Remove the RH fuel tank shield.
^ Remove the 7 bolts.
^ Remove the 2 nuts.





7. Release the fuel tank breather hose from the fuel tank filler pipe.
^ Remove and discard the clip.





8. Position a container to collect the fuel spillage.
9. Disconnect the fuel tank filler pipe hose from the fuel tank filler pipe.
^ Release the clip.





10. Remove the container.
^ Dispose of the collected fuel in accordance with local regulations.
^ Clean any fuel residue remaining in the container.

11. Release the air suspension pipes from the fuel tank filler pipe.
^ Remove and discard the 3 tie straps.

12. Remove the fuel tank filler pipe from the vehicle body.
^ Remove the 2 nuts.
^ Disconnect the breather hose from the fuel tank filler pipe.

Installation
1. Install the fuel tank filler pipe to the vehicle body.
^ Install the nuts.
^ Connect the breather hose to the fuel tank filler pipe.
^ Install the clip.

2. Secure the air suspension pipes to the fuel tank filler pipe.
^ Install new tie straps.

3. Install the fuel tank filler pipe hose to the fuel tank filler pipe.
4. Secure the breather hose to the fuel tank filler pipe.
^ Install a new clip.

5. Install the RH fuel tank shield.
^ Tighten the nuts and bolts to 25 Nm (18 ft. lbs.).

6. Install the RH rear fender splash shield.
7. Install the rear driveshaft.
8. Fill the fuel tank with the amount recovered during the fuel tank drain procedure.
9. Connect the battery ground cable.