How do I replace fuel filler tube? - Cars & Trucks

Brother John, you've removed as much as you can for access to the filler. Remove the hose clamps/bands that secure the fill tube and vent tube and then remove the screws around the gas cap that secure the fill tube to the body. With the gas cap off, go below and pull the hose and filler neck down and work the hoses lose with a pair of channel lock pliers and sticking a screwdriver between the metal tube and hose to break the seal. Put on the new filler neck and stick it back up in the body and put the screws back in. THEN put the hose clamps back up and tighten them, put the gas cap back on and your done.

Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type 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.

1. Remove the fuel tank filler cap.
2. Loosen the right-hand rear wheel nuts.
3. Raise and support the vehicle.
4. Remove the wheel.
5. Remove the fender splash shield.
6. Remove the fuel tank.
7. Partially lower the rear suspension crossmember.
8. Disconnect the fuel vapor tube from the fuel filler pipe.
9. Cut the cable ties.
10. Detach the tube from the clips.
11. Disconnect the vapor tube.
12. Remove the fuel filler pipe lower bolt.
13. Remove the fuel filler pipe center bolt.
14. Disconnect the fuel filler pipe ground cable.
15. Remove the fuel filler pipe.

Reverse to re-install.

THE FUEL FILLER TUBE SEAL WHERE GAS CAP LEAKING OR THE THE TOP LARGE O - RING SEAL ON TOP OF FUEL TANK TO THE FUEL FILTER HAS A EVAP LEAK.

my 2004 dodge ram 1500 2x2with a hemi 5.7 will not accept fuel.As soon as i start to fill it backs up the filler and stops the pump.the only way i can fill the tank is to hold the fuel nozzel out of the hole ans slowly shoot the fuel into the filler tube.This is not only unsafe for my wife and kids but very time consuming.replaced fuel fill tube already and had breather tube blownout and scoped by a mechanic.He now tells me i need a new $500 gas tank.Is this something i can have the dealership fix for free?

open the fuel cover and remove the bolts.Remove the ground strap from the filler tube from under the car.Remove the hose clamps to the rubber hose going into the tank and pull off the hose.Now the filler tube will come out[ if has'nt already fallen out and hit you in the head].

Another filter in the tank?

P0455 - EVAP Control System Leak Detected (No Purge Flow or Large Leak) The PCM monitors the complete EVAP control system for no purge flow, the presence of a large fuel vapor leak or multiple small fuel vapor leaks. The system failure occurs when no purge flow (attributed to fuel vapor blockages or restrictions), a large fuel vapor leak or multiple fuel vapor leaks are detected by the EVAP running loss monitor test with the engine running (but not at idle).

• After-market EVAP hardware (such as fuel filler cap) non-conforming to required specifications
• Disconnected or cracked fuel EVAP canister tube, EVAP canister purge outlet tube or EVAP return tube
• EVAP canister purge valve stuck closed
• Damaged EVAP canister
• Damaged or missing fuel filler cap
• Insufficient fuel filler cap installation
• Loose fuel vapor hose/tube connections to EVAP system components
• Blockages or restrictions in fuel vapor hoses/tubes (items also listed under disconnections or cracks)
• Fuel vapor control valve tube assembly or fuel vapor vent valve assembly blocked
• Canister vent (CV) solenoid stuck open
• Mechanically inoperative fuel tank pressure (FTP) sensor

Check for audible vacuum noise or significant fuel odor in the engine compartment or near the EVAP canister and fuel tank. ----------------------------------------------------------------------------- HX43 DTC P0457: CHECK FOR MISSING OR LEAKING FUEL FILLER CAP

• Check for missing fuel filler cap.
• Check for loose fuel filler cap.
• Check for possible cross-thread fuel filler cap condition.

Is a fault present concerning the proper installation of the fuel filler cap? Yes No REPLACE cross-threaded or damaged fuel filler cap. RECONNECT and TIGHTEN the fuel filler cap only one eighth turn so that the cap initially clicks by sound or touch. CLEAR Continuous Memory DTCs. COMPLETE an Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle (refer to Section 2 , Drive Cycles). RERUN Quick Test . If DTC P0455 or P0457 is present, Go to HX44 . CLEAR Continuous Memory DTCs. COMPLETE an Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle (refer to Section 2 , Drive Cycles). RERUN Quick Test .

For DTC P0455 still present: Go to HX44 .

Otherwise, INFORM the vehicle owner that it is important and necessary to immediately install the fuel filler cap after every refueling event. HX44 DTC P0455: VISUAL INSPECTION FOR SUBSTANTIAL EVAPORATIVE EMISSION SYSTEM LEAKS

• Check for missing fuel filler cap. If the cap is loose DO NOT DISTURB EVAP system.
• Verify that both the input port vacuum hose and EVAP return tube are attached to the EVAP canister purge valve. Note: If the EVAP canister-CV solenoid assembly is not accessible during this pinpoint test step, GO to Evaporative Emissions, Section 303-13 in the Workshop Manual for removal and installation instructions.
  
• Verify that the CV solenoid is properly seated on the EVAP canister (if possible).
• Visually inspect for disconnected or cracked fuel vapor hoses/tubes between the intake manifold, the EVAP canister purge valve, the EVAP canister, the fuel vapor vent valve assembly and if applicable the fuel vapor control valve tube assembly.
• Check for damage to the fuel filler pipe and the fuel tank.

Is a fault indicated? Yes No CONNECT or REPLACE fuel vapor hoses/tubes as required. REPLACE damaged EVAP system components (fuel filler pipe, fuel vapor vent valve assembly, fuel vapor control valve tube assembly, EVAP canister purge valve, FTP sensor and EVAP canister-CV solenoid assembly) as necessary. REFER to Evaporative Emissions, Section 303-13 in the Workshop Manual for removal and installation instructions. GO to HX45 . GO to HX45 . HX45 DTC P1443 and P0455: CHECK FOR EVAPORATIVE EMISSION SYSTEM LEAKS

Note: When checking for leaks or blockages in the EVAP system, energize (close) the canister vent (CV) solenoid through the scan tool for a maximum of nine minutes per pinpoint test step. Then de-energize the CV solenoid prior to performing the subsequent pinpoint test step. This is done to assure proper closing of the solenoid.

• Disconnect and plug the EVAP return tube (EVAP canister purge valve to intake manifold) at the intake manifold vacuum source.
• Connect scan tool.
• Key on, engine off.
• Access VPWR PID. If the voltage is not 12 volts or greater, GO to HX61 .
• Locate evaporative test port [marked EVAPORATIVE SERVICE PORT DO NOT USE UNREGULATED PRESSURE ABOVE 6.89 kPa (1 PSI)] near EVAP canister purge valve or EVAP canister.
• If vehicle is not equipped with the evaporative test port, GO to HX50 .
• Install the Rotunda Evaporative Emission System Leak Tester 310-F007 (134-00056) or equivalent at the evaporative test port.
• Close CV solenoid by accessing Output Test Mode on the scan tool.
• Select ALL OFF mode and push START button.
• Regulate the nitrogen or argon gas pressure on the tester to 3.48 kPa (14 in-H 2 O).
• Follow the instructions that come with the EVAP System Leak Tester and pressurize the EVAP system.
• Perform the EVAP system leak test.

Does the pressure on the EVAP system stay above 1.99 kPa (8 in-H 2 O) and pass the leak test? Yes No GO to HX46 . REMOVE the EVAP System Leak Tester from the evaporative test port and REINSTALL the test port cap. GO to HX50 .

Possibly the fuel filler tube hose is split, between the tank and filler tube ?

Good luck !

Don´t forget to give me a FixYa rating please !

John.

i had the same problem on my 2003 vibe... they replaced the filler tube also and it didn't fix it then they replaced the entire fuel filling system including the venting tupe and located a bee hive honeycomb in the vent line and that was what was causing the problem and have no problems since. hope this helps.

Are you going to get a new one, or a junkyard replacement?
You have to take off the rear left tire. Secure the car with jack stands and chucks. There is a plastic cowl on the wheel-well that covers the filler tube to prevent road damage. Take it off. The filler tube is attached to the gas tank through a rubber connector hose (tube) adapter, secured to the gas tank and to the filler tube by hose clamps. Loosen both clamps.. You should replace the rubber connector, as it has been there for many years, and rubber degrades. Loosen about three or four bolts along the filler tube that attach it to the car body. The top part, by the gas lid, comes off easily, it's just a plastic dam. You have to carefully work it off the (other end) at the rubber hose connector. Once it's out, get the hose connector off the gas tank neck.
With the new filler tube, reverse the process. Getting the hose clamp tight over the gas tank neck is hard. Make sure the clamp is seated properly before tightening.
Good luck!