Procedures
FUEL TANK DRAININGSpecial Tool(s)
Special Tool(s):
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.
- 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.
- 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.
Vehicles with a saddle-type tank
1. With the vehicle in NEUTRAL, position it on a hoist.
All vehicles
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.
4. Release the fuel tank filler cap and position aside.
5. NOTE:
- When the fuel tank is completely full, this step will remove approximately 1/8 of the fuel from the fuel tank.
- The special tool must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank spout, opening the check valve allowing fuel tank drainage. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.
Insert the special tool into the fuel tank filler pipe.
- Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) module mounting flange.
6. Remove the rear seat lower cushion.
7. Remove the FP module access cover.
8. 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.
9. Disconnect the fuel vapor tube assembly-to-FP module quick connect coupling.
10. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the fuel tank jumper tube-to-FP module quick connect coupling.
All wheel drive (AWD) vehicles
11. Remove the driveshaft.
Vehicles with a saddle-type tank
12. Disconnect the fuel tank jumper tube-to-fuel tube quick connect coupling.
13. Remove the evaporative emission (EVAP) canister.
14. Position a suitable lift device under the fuel tank.
15. Remove the 2 front fuel tank strap bolts.
- To install, tighten to 35 Nm (26 lb-ft).
16. NOTE: Install suitable caps on the FP module ports to avoid fuel spillage when lowering the front of the fuel tank.
Partially lower the front of fuel tank.
17. Remove the 3 nuts and the FP module shield.
- To install, tighten to 9 Nm (80 lb-in).
18. NOTE: The fuel tank must be placed back into the installed position prior to FP module removal to avoid fuel spillage.
Raise the fuel tank into the installed position and reinstall the 2 fuel tank strap bolts.
All vehicles
19. NOTE:
- Carefully install the special tool to avoid damaging the FP module when removing the lock ring.
- Carefully remove the FP module lock ring and verify that enough fuel has been removed to avoid fuel spillage.
Install the special tool and remove the FP module lock ring.
20. CAUTION: The fuel pump (FP) module must be handled carefully to avoid damage to the float arm and filter.
Position the FP module aside, insert the tube from the fuel storage tanker into the FP module aperture and remove as much fuel as possible from the fuel tank.
Vehicles with a saddle-type tank
21. Remove the fuel level sensor access cover.
22. NOTE: Clean the fuel level sensor connections, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the fuel level sensor electrical connector.
23. NOTE:
- Carefully install the special tool to avoid damaging the fuel level sensor when removing the lock ring.
- Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Install the special tool and remove the fuel level sensor lock ring.
24. Position the fuel level sensor aside, insert the tube from the fuel storage tanker into the fuel level sensor aperture and remove as much of the remaining fuel as possible from the fuel tank.
