Fuel Tank and Filler Pipe

FUEL TANK AND FILLER PIPE

Special Tool(S):

SPECIAL TOOL(S)

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

REMOVAL
1. If the fuel tank is being removed, remove the driveshaft.







2. To remove individual components, only carry out the listed steps.

Part 1:

Part 2:

3. Illustration 1 of 2. Remove the components in the order indicated in the illustration and table.

Part 1:

Part 2:

4. Illustration 2 of 2. Remove the components in the order indicated in the illustration and table.

Item 1: Fuel Filler Cap Removal Note







1. Using the special tool, drain the fuel from the passenger side of the fuel tank.

Item 5: Fuel Filler Pipe Removal Note

1. Remove the right rear well inner fender splash shield.







2. CAUTION: Some fuel will remain in the filler pipe after draining the fuel tank. Carefully drain the filler pipe into an approved container.

Loosen the clamp at the fuel tank filler pipe and remove the filter pipe.

Item 6: Fuel Tube Shield Removal Note







1. Position the fuel tube shield aside.
1 Remove the pin-type retainers.
2 Remove the bolt.

Item 9: Fuel Tank Strap Mounting Bolt Removal Note







1. Position a suitable lifting device to support the fuel tank.

Item 14: Quick-Connect Fitting Removal Note







1. Partially lower the fuel tank and disconnect the vapor tube.

Item 16: Fuel Transfer Pump Electrical Connector Removal Note

1. Remove the rear seat cushion.







2. Remove the fuel transfer pump access cover.

Item 17: Fuel Transfer Pump Lock Ring Removal Note







1. Remove the bolts and nuts and position the exhaust heat shield onto the exhaust system.







2. Loosen the right fuel tank support strap approximately one inch.







3. Loosen the left fuel tank support strap approximately one inch.







4. Using the special tool, remove the lock ring.

Item 18: Fuel Crossover Hose Quick-Connect Fitting Removal Note







1. NOTE: The routing of the internal fuel crossover hoses is critical to correct fuel system operation. Note the routing of the internal fuel crossover hoses at this time.

Partially raise the fuel transfer pump and disconnect the internal fuel crossover hose quick-connect fittings.

Item 20: Fuel Transfer Pump Gasket Removal Note







1. Using the special tool and a suitable fuel recovery system, drain the fuel from the driver side of the fuel tank.

Item 21: Fuel Delivery Tube Removal Note

1. Remove the fuel delivery module access cover.

Item 23: Fuel Delivery Module Lock Ring Removal Note







1. Using the special tool, remove the fuel delivery module lock ring.







2. Using the special tool and a suitable fuel recovery system, drain the fuel from the passenger side of the fuel tank.

Item 24: Fuel Delivery Module Removal Note

1. CAUTION: Drain the remaining fuel from the fuel delivery module into the fuel tank prior to removal.

Remove the fuel delivery module and fuel crossover hoses as an assembly.

INSTALLATION
1. To install, reverse the removal procedure.
2. Fill the fuel tank.
3. Turn the ignition key to the ON position to pressurize the fuel system.
4. Visually inspect the fuel system for leaks.

Item 24: Fuel Delivery Module Installation Note

1. Install the fuel delivery module and fuel crossover hoses as an assembly. Route the fuel crossover hoses into the driver side of the fuel tank so they are visible within the fuel transfer pump opening.

Item 23: Fuel Delivery Module Lock Ring Installation Note








1. Using the special tool, install the fuel delivery module lock ring.

Item 19: Fuel Transfer Pump Installation Note

1. Partially install the fuel transfer pump.

Item 18: Fuel Crossover Hose Quick-Connect Fittings Installation Note







1. NOTE: Make sure that the fuel crossover hoses are routed correctly.

Raise the fuel transfer pump and connect the fuel crossover hose quick-connect fittings.

Item 17: Fuel Transfer Pump Lock Ring Installation Note







1. Using the special tool, install the fuel transfer pump lock ring.

Item 6: Fuel Tube Shield Installation Note







1. Install the fuel tube shield.
1 Install the pin type retainers.
2 Install the bolt.