Procedures

Fuel Tank Draining





WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release Service and Repair.

2. Disconnect the battery ground cable.

3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.

4. NOTICE: When removing the Fuel Draining Hose, the fitting on the end of the hose can become detained by the safety valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.

NOTE: The Fuel Draining Hose must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank, opening the safety valve.

Insert the Fuel Draining Hose into the fuel tank filler pipe.





5. NOTE: This step will remove approximately one-eighth tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe.

Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove as much fuel as possible from the fuel tank and fuel tank filler pipe.

6. Remove the rear seat lower cushion.

Front Wheel Drive (FWD) vehicles

7. Remove the 4 screws and the Fuel Pump (FP) module access cover.





All-Wheel Drive (AWD) vehicles

8. Remove the 3 screws and the FP module access cover.





All vehicles

9. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.

Disconnect the FP module electrical connector.





10. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

Disconnect the fuel tube-to-FP module quick connect coupling.





11. NOTE: Make sure to install a new FP module O-ring seal and lock ring.

Install the Fuel Tank Sender Unit Wrench, remove and discard the FP module lock ring.





12. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

Position the FP module aside and insert the tube from the fuel storage tanker into the FP module aperture and drain as much fuel from the fuel tank as possible.





AWD vehicles

13. Remove the 3 screws and the fuel level sensor access cover.





14. NOTE: Clean the fuel level sensor connection, flange surface and the immediate surrounding area of any dirt or foreign material.

Disconnect the fuel level sensor electrical connector.





15. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.

NOTE: Make sure to install a new fuel level sensor O-ring seal.

Release the lock tab, and using a suitable tool, rotate the fuel level sensor counterclockwise approximately one-fourth turn, lift and position aside.





16. Insert the tube from the Fuel Storage Tanker into the fuel level sensor aperture and drain the remainder of the fuel from the fuel tank.