FUEL TANK FILLER DOOR, FILL PIPE ASSEMBLY, AND FILL/VENT HOSES
REPLACEMENT (ALL EXCEPT M1009 AND M1010).
This task covers:
Both battery negative cables disconnected.
Screwdriver bit set, J-29843
(See paragraph 4-38)
Fuel tank drained halfway.
General Safety Instructions
DO NOT perform this procedure near fire, flames, or sparks.
Always wear goggles when working on underside of truck.
Diesel fuel is flammable. DO NOT perform this procedure near fire,
flames, or sparks. A fire extinguisher must be on hand in work area.
Failure to follow this warning may result in serious injury or death.
Always wear goggles when working on underside of truck. Fuel spillage
can occur when disconnecting fuel lines. Failure to follow this warning
may result in serious eye injury.
Loosen clamps (10 and 11), and disconnect fill hose (9) and vent hose (12) from fuel tank.
Remove 3 screws (4), and remove housing (6), fill pipe assembly (7),
(9) and vent hose (12).
Remove 2 bolts (2) and remove door assembly (3).
Remove any door bumpers (1) if damaged.
Inspect fill pipe assembly (7) for cracks or punctures.
Inspect fill hose (9) and vent hose (12) for cracks, punctures, or soft
Remove 2 clamps (8 and 13) and 3 screws (5), and disassemble
assembly (7), fill hose (9), and vent hose (12) only as required
components. Note position of hoses for assembly.
Install new door bumpers (1) if removed.
and attached fill hose
housing (6), fill pipe
to replace damaged