Service Procedure
CAUTION:^ The fuel tank should have less than tank of fuel before starting this procedure.
^ Use protective covers as needed when working inside the vehicle.
WARNING:
^ When working on the fuel system, put a "CAUTION: FLAMMABLE" sign in the work area.
^ Make sure the work area is well ventilated, and a fire extinguisher is available in the work area.
^ Do not smoke while working on the fuel system. Also, keep open flames and sparks away form the work area.
^ Follow all warnings and cautions in the Service Manual when working on the fuel system.
1. Write down all radio station settings.
2. Write down / record the customer settings for the Automatic Air Conditioning System or Advanced Climate Control System. Refer to the Service Manual as needed.
3. Release fuel system pressure as follows:
a. Turn the ignition ON.
b. Using CONSULT III plus; perform "FUEL PRESSURE RELEASE" in "WORK SUPPORT" mode of "ENGINE".
c. Start the engine.
d. After engine stalls, crank it two or three times to release all fuel pressure.
e. Turn the ignition OFF.
4. Disconnect the negative battery cable.
5. Remove the fuel fill cap to release pressure in the tank, and then reinstall the fuel fill cap.
6. Move the 2nd row seats as far forward as possible.
7. Remove 2 left rear floor duct trim.
^ Pull to unsnap.
^ Use a plastic trim tool as needed.
8. Remove the floor mat.
9. Snap loose and remove the rear seat track covers for the left side 2nd row seat.
^ Use a plastic trim tool as needed.
10. Pull back the carpet to expose the left side rear vent duct.
11. Remove the left side rear vent duct.
a. Remove screw.
b. Pull duct to the left to remove.
12. Remove the fuel pump inspection cover.
a. Turn the 4 retainers (A) 90 degrees to release.
b. Lift the cover.
c. Disconnect the fuel pump electrical connector.
d. Place the fuel pump cover to the side and out of the way.
13. Place protective cloth / rags around the fuel pump opening.
NOTE:
^ When the fuel pump is removed, some fuel will spill from the pump.
^ The rags around the pump opening will absorb the small fuel spill and protect the vehicle interior.
14. Disconnect the EVAP hose and the fuel feed hose.
^ Be careful; some fuel may leak from the hoses when they are disconnected.
^ Push in on the tabs and pull on the hose.
^ If the hose is stuck, push and pull the hose to release it.
^ Cover the hose ends to prevent debris entry.
15. Remove the fuel pump lock ring.
^ Use special tool J-45747.
^ Turn counterclockwise.
^ Remove lock ring from the top of the fuel pump.
NOTE:
^ In the next steps you will be removing and then reinstalling the fuel pump assembly to make sure the transfer hose inside the fuel tank is routed correctly.
^ Figure 13 is provided to help understand the correct routing of the transfer hose.
16. Turn the fuel pump assembly 1/4 turn counterclockwise, so the fuel feed tube is pointing toward the rear of the vehicle.
17. Remove the fuel pump from the tank.
^ Tilt the top of the pump toward the driver side to clear the float arm through the tank opening.
CAUTION:
^ When the fuel pump assembly is removed, some fuel will spill from the assembly.
^ Rags around the fuel pump opening will absorb the small fuel spill and protect the vehicle interior.
18. Check the transfer hose position / routing as follows:
a. Hold the fuel pump assembly so it is oriented the same as it would be inside the tank (float arm facing forward).
b. Make sure the transfer hose bends toward the passenger side of the vehicle as shown in Figure 16a.
^ If the transfer hose is straight down or bends toward the driver side as shown in Figure 16b, twist the hose with your fingers so it is routed / positioned as shown in Figure 16a.
19. Reinstall the fuel pump as follows:
CAUTION:
It is important that the fuel pump be installed carefully, according to the method in this step to prevent the transfer hose from being pinched under the fuel pump and to ensure it is routed correctly inside the tank.
NOTE:
Figure 17 is provided (fuel tank cut open) to show the correct transfer hose routing inside the fuel tank.
a. Install a new fuel pump O-ring seal.
b. Obtain a piece of plastic or nylon packing strap about 3 feet (36 inches, 91 cm) long.
^ Packing strap is commonly used to reinforce boxes for shipping.
c. Loop the packing strap around the transfer hose as shown in Figure 19.
^ Position the strap ends toward the passenger side.
^ Use your fingers to put a bend in the strap near the transfer hose. This will help keep the strap in place.
d. Lower the transfer hose and the fuel pump into the tank keeping the strap looped around the transfer hose.
e. With the pump in the tank, turn it 1/4 turn clockwise so the fuel feed tube is pointing toward the driver side.
^ The pump should now be oriented to the installed position.
f. Tilt the top of the fuel pump toward the driver side.
g. Pull up on the packing strap (pull the transfer hose up) just enough to see the transfer hose (see Figure 22).
NOTE:
If you are unable to pull the transfer hose so it can be seen as shown in Figure 22, remove the fuel pump from the tank and restart from the beginning of step 19.
h. Hold the fuel pump down so the bottom of the pump stays against the bottom of the tank.
i. While holding the pump down, pull out the packing strap. Pull toward the passenger side.
^ Make sure the O-ring seal is still in place.
j Continue to hold down the fuel pump while installing the fuel pump lock ring.
^ Use special tool J-45747 to secure the lock ring.
^ Turn clockwise.
NOTE:
^ If the fuel pump is allowed to lift off of the bottom of the fuel tank the transfer hose may slide under it.
^ If the fuel pump lifts off the bottom of the tank before the lock ring is installed, remove the fuel pump and restart from the beginning of step 19.
20. Reconnect the EVAP hose and the fuel feed hose.
^ Make sure the hose retainer is in place and then push the hose onto the fuel pump tube (port).
CAUTION:
^ After connecting fuel tube quick connectors, make sure quick connectors are secure.
^ Ensure that connector and resin tube do not contact any adjacent parts.
21. Reconnect the fuel pump electrical connector.
22. Check for fuel leaks.
a. Connect the negative battery cable.
b. Start the engine.
c. Check for fuel leaks.
d. Turn the ignition OFF.
e. If needed, repair fuel leak.
23. Install / secure the fuel pump inspection cover.
^ Turn the 4 retainers (A) 90 degrees to secure.
24. Reinstall other parts:
^ Left rear floor duct
^ Carpet
^ Left rear seat track covers
^ Left rear floor duct trim
^ Floor mat
25. Reinitialize each auto-up power window as follows:
a. Turn ignition ON.
b. Open window all the way DOWN.
c. Pull all the way UP on the switch and HOLD (close the window completely), continue to HOLD for 4 seconds after window is completely closed.
d. Confirm auto up/down operates correctly.
26. Reset the clock and the radio station presets.
27. Reset the customer settings for the Automatic Air Conditioning System or Advanced Climate Control System. (Refer to the Service Manual as needed):
28. Inform the customer they will need to reset their Auto Drive Position (ADP) settings and navigation memory settings.