Late Build
FUEL TANK AND FILLER PIPESpecial Tool(s):
SPECIAL TOOL(S)
REMOVAL
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. Failure to follow these instructions may result in personal injury.
- The evaporative emissions system contains fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground to minimize the possibility of an electrical spark occurring, possibly causing fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the battery ground cable.
3. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
If removing the fuel tank, it will be necessary to release the fuel system pressure.
4. If removing the fuel tank, it will be necessary to release the fuel tank fill hose clamp and disconnect the fuel filler hose from the fuel filler pipe assembly.
5. If removing the fuel tank, it will be necessary to use the special tool and siphon the fuel through the lower fuel filler hose into a suitable container.
6. If equipped, remove the transfer case skid plate by removing the four bolts from the outer frame rail (two per side).
Part 1:
Part 2:
7. Remove the parts in the order indicated in the illustrations and tables. To remove individual parts, only carry out the listed steps.
Item 3: Vapor Tube Removal Note
1. Carefully twist and pull the vapor tube from the fuel filler pipe housing. This can be accessed through the wheelwell.
Items 4, 12 and 23: Quick-Connect Fitting Removal Note
1. CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
- When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube.
NOTE: If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel tube disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body.
Disconnect the quick-connect fitting.
- Push the connect toward the tube to release the pressure.
- Press the locking button and pull the fuel tube to disconnect.
Item 10: Fuel Filler Pipe Assembly Removal Note
1. The fuel tank filler pipe assembly is removed as a complete unit. Do not disassemble.
Item 11: Fuel Supply Tube Removal Note
1. Remove the bolts and the heat shield.
2. Remove the bolts and the fuel filter shield.
3. 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 servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which can cause personal injury or a fire hazard.
Disconnect the safety clip.
4. Install the special tool and push it into the fitting.
5. Separate the fitting.
- Inspect the damage.
- Clean the fittings.
Items 20 and 22: Front Support Strap and Fuel Tank Removal Note
1. Use a suitable jack to support and lower the fuel tank.
2. Lower the tank enough to disconnect the fuel pump electrical connector then finish lowering the fuel tank.
Items 24-26: Fuel Pump Module Locking Ring, Fuel Pump Module, and O-ring Seal Removal Note
1. Using the special tool, remove the fuel pump module locking ring.
2. NOTE: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter.
Remove the fuel pump module.
INSTALLATION
1. To install, reverse the removal procedure.
Items 26-24: Fuel Pump Module Locking Ring, Fuel Pump Module, and O-ring Seal Installation Note
1. Lubricate the fuel pump module O-ring seal with clean engine oil prior to installation.
2. NOTE: The fuel pump module must be handled carefully to avoid damage to the float arm and the filter.
Install the fuel pump module.
3. NOTE: The fuel pump module locking ring is a cam-lock type. Turn the locking ring until it stops and is locked in place.
Using the special tool, install the fuel pump module locking ring.
Items 23, 12 and 4: Quick-Connect Fitting Installation Note
1. CAUTION:
- Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes.
- Make sure the quick-connect fitting clicks into place when installing the tube. To make sure that the quick-connect fitting is fully seated, pull on the tube.
NOTE:
- If the fuel tube retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retaining clip legs. Once the retainer legs have been separated, lift the clip out of the connect housing, lifting from the stamped side of the connector body.
- Apply clean engine oil to the end of the tube before connecting the fitting.
Connect the quick-connect fitting.
Item 11: Fuel Supply Tube Installation Note
1. Align the fuel tube fitting and push together until a click is heard.
2. Pull on the fitting to make sure it is fully engaged. Install a safety clip.
Item 10: Fuel Filler Pipe Assembly Installation Note
1. The fuel filler pipe assembly is to be installed as a complete unit. Do not disassemble.