System Overview
Two fuel tanks store the fuel supply. An electric fuel pump attaches to the fuel sender assembly inside the left fuel tank. The fuel pump pumps fuel through the fuel feed pipe and an in-line fuel filter to the fuel rail. The rear fuel feed pipe has an integral check valve in order to maintain fuel system pressure in the feed pipe. The pump provides fuel at a pressure greater than is needed by the fuel injectors. The fuel pressure regulator, part of the fuel rail, keeps fuel available to the injectors at a regulated pressure. A fuel return pipe returns the unused fuel to the left fuel tank. The fuel pump also feeds fuel through a tee in the fuel feed pipe and through the fuel feed rear crossover pipe in order to supply the siphon jet pump inside the right fuel tank. The siphon jet pump transfers fuel from the right fuel tank to the left fuel tank through the fuel sender fuel feed pipe.
Fuel Tank Vent Valve
The fuel tank vent valve is located in the rear of the vehicle behind the right rear wheelhouse liner panel. The fuel tank vent valve is a pressure relief valve. When the fuel tank pressure exceeds a specified pressure, the valve opens allowing the tank pressure to bleed off.
Fuel Tanks
The fuel tanks store the fuel for the vehicle. The fuel tanks are located on the left and right side of the vehicle in front of the rear wheels. The fuel tanks are molded from high density polyethylene.
Fuel Tank Fill and Vent Pipe and Hoses
The fuel tank fill and vent pipe (1) is positioned at the rear of the vehicle on the left side. A built in restrictor in the fuel tank fill pipe prevents refueling with leaded fuel. The fuel tank fill and vent pipes connect to the left fuel tank with rubber hoses (3 and 4). Fuel transfers to the right fuel tank during fueling by a large rubber crossover hose which connects the left fuel tank to the right fuel tank.
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 tank filler pipe has a tethered fuel tank filler cap. The fuel tank filler cap requires a quarter of a turn to remove it. A torque limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until the cap is fully seated.
Fuel Sender Assembly
A fuel sender assembly is located inside each fuel tank. The fuel sender assembly attaches to the lower side of each fuel tank. The left fuel sender assembly consists of the following major components:
| • | The fuel sender. |
| • | The fuel pump and reservoir assembly. |
| • | The fuel pump strainer. |
The right fuel sender assembly consists of the following major components:
| • | The fuel sender. |
| • | The siphon jet pump. |
| • | Two fuel strainers. |
Fuel Sender
The fuel sender consists of a float, a wire float arm, and a fuel level sensor. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance corresponding to the amount of fuel in the fuel tank. The PCM uses inputs from both fuel senders in order to calculate the total fuel remaining in both fuel tanks. This information is sent via serial data to the Instrument Panel Cluster (IPC) to be displayed on the fuel gauge.
Fuel Pump
An electric high pressure fuel pump attaches to the fuel sender assembly inside the left fuel tank. The fuel pump pumps fuel to the fuel rail assembly at a specified flow and pressure. Excess fuel from the fuel rail assembly returns to the left fuel tank through 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 left tank fuel pump also supplies a small amount of pressurized fuel to the right fuel tank siphon jet pump through the fuel feed rear crossover pipe. The pressurized fuel creates a venturi action inside the siphon jet pump. The venturi action causes the fuel to be drawn out of the right fuel tank. Fuel is then transferred from the right fuel tank to the left fuel tank through the fuel sender fuel feed pipe.
Fuel Strainer
The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The left fuel sender assembly has a large L-shaped strainer. The right fuel sender assembly has two strainers. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank(s) contains an abnormal amount of sediment or water. If a fuel strainer is plugged, refer to Fuel System Cleaning .
Fuel Filter
A plastic fuel filter is installed in the fuel feed pipe ahead of the fuel injection system. The paper filter element (2) traps particles in the fuel that may damage the fuel 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.
Fuel Feed and Return Pipes
The fuel feed pipe carries fuel from the left fuel tank to the fuel rail assembly and to the right fuel tank siphon jet pump. The fuel return pipe carries fuel from the fuel rail assembly back to the left fuel tank. The fuel feed and return pipes consist of three sections:
| • | The rear fuel pipes are located from the left fuel sender assembly to the chassis fuel pipes and from the left fuel sender assembly to the right fuel sender assembly. The rear fuel pipes connecting the fuel sender assemblies are constructed of sections of steel pipe and nylon pipe. The rear fuel pipes connecting the left fuel sender assembly to the chassis fuel pipes are constructed of nylon. The rear fuel feed pipe has an integral check valve in order to maintain fuel system pressure in the feed pipe. |
| • | The chassis fuel pipes are located under the vehicle on the left side of the tunnel. The chassis fuel pipes connect the rear fuel pipes from the left fuel sender assembly to the engine compartment connecting fuel pipes. These pipes are constructed of aluminum with a plastic coating. |
| • | The engine compartment connecting fuel pipes connect the chassis fuel pipes to the fuel rail assembly. These pipes are constructed of Teflon® with a braided stainless steel covering. |
Nylon Fuel Pipes
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
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. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. 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 two sizes of nylon fuel pipes used. A 3/8 in ID pipe is used for the fuel feed pipe and the fuel sender fuel feed pipe (jet pump to left tank). A 5/16 in ID pipe is used for the fuel return pipe and the fuel feed rear crossover pipe (left tank to jet pump). Heat resistant rubber hose and/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 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. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs or fingers hold the fittings together.
EVAP Pipes and Hoses
Caution: In order to Reduce the Risk of Fire and Personal Injury:
• If nylon fuel pipes are nicked, scratched or damaged during installation,
Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. • When installing new fuel pipes, Do Not hammer directly on the
fuel harness body clips as it may damage the nylon pipes resulting in a possible
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. • Before connecting fuel pipe fittings, always apply a few drops
of clean engine oil to the male pipe ends. 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.)
A roll over valve is molded into the top of each fuel tank. The rear EVAP pipes extend from each roll over valve to the fuel tank vent valve and to the evaporative emission canister. The rear EVAP pipes are made of plastic with a Teflon® barrier. The fuel tank vent valve pipe connects to the fuel tank vent valve with a section of fuel resistant rubber hose. The chassis EVAP purge pipe extends from near the EVAP canister to the engine compartment. The chassis purge pipe is made of aluminum with a plastic coating.
