Fuel Tank
The fuel tank, at the rear of the underbody, is held in place by two metal straps. Insulators are used on the fuel tank in order to reduce rattles.
Fuel Fill Pipe
The fuel fill pipe on gasoline engine equipped vehicles has a built-in restrictor and deflector in order to help prevent refueling with leaded gasoline. The opening in the restrictor will only admit the smaller unleaded gas nozzle spout, which must be fully inserted to bypass the deflector. Attempted refueling with a leaded gas nozzle or failure to fully insert the unleaded gas nozzle results in gasoline splashing back out of the filler neck.
Fuel Filler Cap
Notice: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system.
The fuel fill pipe has a tethered fuel filler cap. Turn the cap counterclockwise in order to remove it. A built-in torque-limiting device prevents overtightening. In order to install the cap, turn the cap clockwise until a clicking noise is heard. The clicking is a signal to the operator that the correct torque has been reached and the cap is fully seated.
Fuel Sender Assembly
The fuel sender assembly is inside the fuel tank attached to the top of the fuel tank. The fuel sender assembly consists of the following major components:
| • | The fuel level sensor (6) |
| • | The fuel tank pressure sensor (1) |
| • | The fuel tank fuel pump module (2) |
| • | The fuel strainer (3) |
Fuel Pump
The fuel pump attaches to the fuel sender assembly reservoir inside the fuel tank. The fuel pump is an electric high pressure pump. The fuel pump pumps fuel to the fuel meter body assembly at a specified flow and pressure. Excess fuel from the fuel meter body returns to the fuel tank through the fuel return pipe. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The control module controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.
Fuel Strainer
The fuel strainer attaches to the lower end of the fuel sender assembly. The fuel strainer is made of woven plastic. The functions of the strainer are to filter contaminants and to wick fuel. The fuel strainer normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Clean the fuel tank and replace a plugged strainer with a new one.
In-Line Fuel Filter
The fuel feed pipe has a steel fuel filter installed ahead of the fuel injection system. The paper filter element (2) traps particles in the fuel that may damage the injection system. The filter housing (1) is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature.
Nylon Fuel and EVAP Pipes
Caution: In order to reduce the risk of fire and personal injury observe the
following items:
• Replace all nylon fuel pipes that are nicked, scratched or damaged
during installation, do not attempt to repair the sections of the nylon fuel
pipes • Do not hammer directly on the fuel harness body clips when installing
new fuel pipes. Damage to the nylon pipes may result in a fuel leak. • Always cover nylon vapor pipes with a wet towel before using a
torch near them. Also, never expose the vehicle to temperatures higher than
115°C (239°F) for more than one hour, or more than 90°C (194°F)
for any extended period. • Apply a few drops of clean engine oil to the male pipe ends before
connecting fuel pipe fittings. This will ensure proper reconnection and prevent
a possible fuel leak. (During normal operation, the O-rings located in the
female connector will swell and may prevent proper reconnection if not lubricated.)
Nylon fuel pipes are designed to perform the same job as the steel or flexible fuel pipes or hoses that they replace. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are three sizes of nylon pipes used: 3/8 in. ID for the fuel feed, 5/16 in. ID for the fuel return and 1/2 in. ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration.
Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes will kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes.
Quick-Connect Fittings
Quick-connect type fittings provide a simplified means of installing and connecting the fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs or fingers hold the fittings together.
Fuel Pipe O-Rings
O-rings seal the threaded connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.
EVAP Pipes and Hoses
The evaporative emission (EVAP) pipes extend from the fuel sender assembly and the EVAP canister to the EVAP purge solenoid in the engine compartment. The EVAP pipes are made of nylon. The EVAP vent solenoid connects to the EVAP canister with a section of fuel resistant rubber hose.
