Contents: Removal ↧ Installation ↧
Removal
Caution: Before disconnecting fuel lines, clean the connectors and surrounding areas to prevent dirt from entering the system.
Series 1500
1. Remove the filler cap.
2. Unscrew the bolts (1) and (2) securing the filler neck cover housing.
3. If necessary, remove the spare wheel lock cylinder.
4. Remove the spare tire if necessary.
5. Raise the vehicle and place safety stands under the frame.
6. Disconnect the clamp (1) securing the main gear ventilation hose from the filler neck pipe.
7. If necessary, disconnect the air suspension hose from the filler neck pipe.
8. Loosen the ground bolt (2) of the chassis wire bundle.
9. Remove the ground cables of the left rear light (4) and the filler pipe (5) from the frame.
10. Disconnect the fuel tank ventilation pipe connector (5) from the filler neck pipe.
11. Loosen the clamp (1) of the filler neck hose.
12. Unscrew the bolts (2) and (3) of the filler neck pipe bracket.
13. Disconnect the filler neck hose from the fuel tank.
14. Plug open holes.
15. If necessary, disassemble the filler neck pipe assembly.
1 - filler neck ventilation hose, 2 - filler neck cap housing bolts, 3 - filler neck cap housing, 4 - filler neck hose, 5 - clips, 6 - clamp, 7 - hose, 8 - clamp, 9 - fuel vapor recovery system hose, 10 - clamp
16. Installation is carried out in reverse order.
Series 2500
1. Remove the rear fuel tank.
2. Loosen the ground bolt (2) of the chassis wire bundle.
3. Remove the ground cables of the left rear light (4) and the filler pipe (5) from the frame.
4. Remove the final drive ventilation hose clamp from the filler neck pipe.
5. Loosen the clamp (1) of the front fuel tank filler hose.
6. Disconnect the fuel vapor recovery system hose connector (2).
7. Remove the front tank fill hose from the front tank.
8. Remove the integral filler neck hose clamp from the crossmember.
9. Remove the filler neck hose and pipe assembly.
10. Plug open holes.
11. If necessary, disassemble the filler neck pipe assembly.
1 - fuel vapor canister hose, 2 - fuel vapor canister hose clamp, 3 - filler neck pipe clamp, 4 - filler neck cap housing bolts, 5 - filler neck cap housing, 6 - filler neck pipe restrictor, 7 - filler neck pipe clamp, 8 - fuel tank ventilation hose, 9 - clamp, 10 - clip, 11 - filler neck pipe, 12 - clamp
Installation
12. Installation is carried out in reverse order.