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, fuel transfer pump or fuel delivery module is being removed drain the fuel tank.
2. If the fuel tank is being removed, remove the driveshaft.

Part 1:

Part 2:

Part 3:

3. Remove the parts in the order indicated in the illustrations and tables. To remove individual components, only carry out the listed steps.

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 8: Fuel Tube Shield Removal Note







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

Item 12: Fuel Tank Strap Mounting Bolt Removal Note







1. Remove the bolts and the heat shield.







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

Item 16: Vapor Tube Quick-Connect Fitting Removal Note







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

Item 23: 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 26: Fuel Delivery Module Removal Note







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

Before removal, attach a non-conductive material to the crossover line. Then remove the fuel delivery module and crossover lines as an assembly, using the non-conductive material to pull the crossover lines through the gas tank.

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 26: Fuel Delivery Module Installation Note

1. NOTE: Install the fuel delivery module and crossover hoses as an assembly.

Attaching the non-conductive material to the crossover lines, pull the crossover lines through the gas tank to install the fuel delivery module.

Item 25: Fuel Delivery Module Lock Ring Installation Note








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

Item 22: Fuel Transfer Pump Installation Note
1. Partially install the fuel transfer pump.

Item 23: 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 21: Fuel Transfer Pump Lock Ring Installation Note







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

Item 8: Fuel Tube Shield Installation Note







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