Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

The fuel tank stores the fuel supply. An electric fuel pump, located in the fuel tank with the fuel level sensor assembly, pumps fuel through an in-line fuel filter to the fuel rail assembly. The pump provides fuel at a pressure greater than is needed by the injectors. The fuel pressure regulator, part of the fuel rail assembly, keeps fuel available to the injectors at a regulated pressure. A separate pipe returns unused fuel to the fuel tank.

The fuel tank stores fuel for the vehicle. The fuel tank is in the rear of the vehicle. Two metal straps attach the fuel tank to the impact bar. The fuel tank consists of a tough pliable polyethylene liner inside a steel container.

The filler pipe is an integral part of the fuel sender. The filler pipe has a built in restrictor to prevent refueling with leaded fuel.

The filler pipe has a threaded-type cap. The threaded part of the cap requires several turns counterclockwise to remove. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear a clicking noise. This indicates that the cap is correctly torqued and fully seated.

Notice: If a fuel tank filler pipe cap requires replacement, use only a fuel tank filler pipe cap with the same features. Failure to use the correct fuel tank filler pipe cap can result in a serious malfunction of the fuel system.

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 sender consists of a filler pipe, a float, a wire float arm, a sensor, and a roll-over valve. The position of the float arm indicates the fuel level. The Central Control Module (CCM) sends a signal to the display in the vehicle instrument cluster. The EVAP pipe of the fuel sender has a pressed in roll-over valve. The roll-over valve prevents fuel from entering the evaporative emission canister if the vehicle rolls over by shutting OFF the EVAP pipe to the canister.

The fuel pump attaches to the fuel sender assembly inside the fuel tank. The fuel pump is a roller vane pump that produces high pressure. The fuel pump pumps fuel to the fuel rail assembly at a specified flow and pressure. Excess fuel returns to the fuel tank by the return pipe. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle maneuvers. The PCM controls the electric fuel pump operation through a fuel pump relay.

The fuel pump strainer attaches to the lower end of the fuel pump. The fuel pump strainer is made of woven plastic. The functions of the fuel pump strainer are to filter contaminants and to wick fuel. The fuel pump strainer is self-cleaning and 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 fuel pump strainer with a new one.

Installed between the fuel pump and the fuel feed pipe on the fuel sender is the fuel pulse dampener. The function of the fuel pulse dampener is to dampen fuel pulsation and reduce noise generated by the fuel pump.

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. There is no service interval for fuel filter replacement. Replace a restricted fuel filter.

The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tank. The fuel feed and return pipes consist of sections of steel pipe and fuel resistant rubber hoses.

Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end on the fuel rail. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs or fingers hold the fittings together.

The EVAP pipe extends from the fuel sender assembly to the evaporative emission canister. The EVAP pipe is made of nylon pipe. The EVAP pipe connects to the fuel sender assembly and the evaporative emission canister with fuel resistant rubber hoses.

Caution: In order to Reduce the Risk of Fire and Personal Injury: