Fuel Tank Filler Pipe - All Wheel Drive (AWD)

Fuel Tank Filler Pipe - All Wheel Drive (AWD)





Removal and Installation

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: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction 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.

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Remove the muffler and tailpipe.

3. Disconnect the battery ground cable.

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

5. 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.





6. NOTE: This step will remove approximately one-eighth tank of fuel from a completely full fuel tank and the majority of any residual fuel from the fuel tank filler pipe. Also, the fuel in the fuel tank will be below the fuel tank inlet for fuel tank filler pipe removal without fuel spillage.

Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove approximately one-eighth tank of fuel (from a completely full tank), lowering the fuel level below the fuel tank inlet.

7. Remove the 3 fuel tank filler pipe retaining screws.

8. Remove the LH rear wheel and tire.

9. Remove the 3 rivets, 6 pin-type retainers and the LH wheel splash shield.

10. Remove the fresh air hose fitting from the fuel tank filler pipe housing.

11. Remove the 3 nuts and the fuel tank filler pipe heat shield.
- To install, tighten to 9 Nm (80 lb-in).

12. Disconnect the fuel vapor tube assembly-to-recirculation tube quick connect coupling.

13. Remove the fresh air hose from the dust separator.

14. Remove the fuel tank filler pipe bracket retaining nut.
- To install, tighten to 10 Nm (89 lb-in).

15. Release the 2 swivel clips.

16. Remove the 4 screws and the fuel tank filler pipe housing.

17. Loosen the LH fuel tank strap bolts.
- To install, tighten to 40 Nm (30 lb-ft).

18. Partially lower the LH side of the fuel tank to allow access to the fuel tank filler hose and clamp.

19. NOTE: Some fuel may remain in the fuel tank filler pipe after the initial drain. Carefully drain any residual fuel into a suitable container.

Release the clamp and disconnect the fuel tank filler pipe hose from the fuel tank.

- To install, tighten to 4 Nm (35 lb-in).

20. NOTE: The fuel tank filler pipe assembly has to be directed upward and partially out of the fuel door opening, then it can be lowered and maneuvered out of the vehicle.

Remove the fuel tank filler pipe assembly from the vehicle.

21. To install, reverse the removal procedure.