Page 1693 of 2490

Filler Cap and P
ipe
The fuel
filler cap with bayonet-type fixi
ng is located beneath a remote-release sp ring-latched lid on the rear saddle panel
on the left-hand-side of the vehicle.
Fuel Pum
p
The fu
el pump(s) is energized by an ECM co
ntrolled relay. Fuel is drawn by this pu mp and supplied to the fuel injectors via
the fuel line, filter and fuel rails.
Servicing of the fuel pump re quires fuel tank removal.
Ev
aporative Loss Flange Assembly
The evaporative-loss flan
ge asse
mbly is mounted centrally on top of the tank. The flange assembly consists of a removeable
steel cap which mounts the evaporative emissions system vapor outlet valves and, if applicable, a pressure sensor. The
external electrical supply to th e fuel pump(s) is also made via a connector on the flange.
The flange assembly is fixed to the tank by a locking ring which is turned usin g special tool JD-174. A seal is fitted between
the flange assembly and the tank. Three di fferent flange assemblies are applicable according to the evaporative emission
system fitted to the vehicle. The fl ange size and fixing are identical fo r the three systems, as described.
Removal of the evaporative flange assembly is necessary to gain access to th e fuel pump(s) and other internal components.
To remove the evaporative fl ange assembly the fuel tank must first be removed.
The evaporative flange variant assemblies are described, together with service information, in Section 303-13.
Fuel R
eturn
Excess fuel
is directed back to
the fuel tank via a return line.
Fuel Pum
p Relay
The
fuel pump relay,
under control of the ECM, switches power to the fuel pump motor.
I
nertia Fuel Shutoff (IFS) Switch
The IF
S switch is located in the right-hand
side footwell behind the footboard carpet . When activated the switch isolates the
ignition system and fuel pump, releases any locked doors and disables unnecessary electrical systems. The system can be
reset by pressing down the flexible cover on the top of the switch.
• NOTE: The doors will not unlock if the IFS switch is tripped when the ignition switch is in position '0'.
Page 1694 of 2490
P a
rts List
The fuel level sensor is mounte d on the fuel tank vertical face and reacts to level changes via a float and pivot which is
connected to a potentiometer. As the fuel level drops the resistance increases.
The fuel level sensor can be serviced without removing the tank.
It e
m
Par
t
Number
De
scr
iption
1—Lockin
g rin
g
2—Fue
l
level sensor
3—Seal
Fuel
Level Sensor
Page 1696 of 2490
Ite
m
Par
t
Number
De
scr
iption
1—Engine
m
anagement ECM
2—Boot fuse box
3—Fue
l
pump
Ci
rcui
t Diagram, Fuel Pump -
Normally Aspirated Vehicles
Page 1697 of 2490
It
em
Par
t Number
De
scription
1—Engine
management ECM
2—Boot fuse box
3—Fue
l pumps
Ci
rcuit Diagram, Fuel Pump
- Supercharged Vehicles
Page 1698 of 2490

Fuel Tank and Lines - Fuel Tank and Li
nes
D
iagn
osis and Testing
Sym
p
tom Chart
Sy
m
ptom Chart
Pinpoint test A: P1230
S
p
ecial Tool(s)
D
i
gital multimeter
Generi
c scan tool
F
u
el tank sender (sensor) unit wrench
18G 1001
Sy m
ptom
Possib
l
e Sources
Acti
o
n
D
T
C P1230 Fuel pump relay
malfunction
Re lay
failure
Harness fault
Connector loose or corroded
Connector pins(s) bent or tracking between connections
Ground failure
*
*
*
*
*
GO to Pinpoint
Test A
*
D
T
C P1646 Secondary fuel pump
relay malfunction
Re lay
failure
Harness fault
Connector loose or corroded
Connector pins(s) bent or tracking between connections
Ground failure
*
*
*
*
*
GO to Pinpoint
Test B
*
D
T
C P0460 Fuel level sensor circuit
malfunction
Worn
or damaged sensor tracks
Harness fault
Connector loose or corroded
Connector pin/s bent or tracking between connections
Fuel level sensor to instrument pack circui ts intermittent short
or open circuit or high resistance. Fuel level sensor failure
Instrument pack fault (inc orrect fuel level data)
*
*
*
*
*
*
*
GO to Pinpoint
Test C
*
P
INPOINT TES
T A : A: P1230
T
E
ST CONDITIONS
D
E
TAILS/RESULTS/ACTIONS
A1
: RETRIEV
E DTCS
•
NOTE
: Battery and or ECM disconnection prior to scanning wi
ll erase all data, ensure that the correct DTC is present.
Page 1702 of 2490
Measure t
he resistance between relay socket pin 5 and
ground BT020L.
1
I s
the resistance < 10OHM?
Yes GO to A6
No GO to A10
A6: CHECK FUEL
PUMP DRAWN CURRENT
•
NOTE
: With EM013 disconnected this test will cause the pump to operate continuously. Do not exceed 10 sec running.
•
NOTE: Do not replace relay.
Page 1707 of 2490
Wi
th BT009 disconnected, measure the resistance across
the fuel pump connectors reference BT009/001 and
BT009/002.
1
I
s the resistance < 5 OHM?
Yes GO to A11
No Renew the fuel pump and te st the system for normal
operation.
A11: CHECK FU
EL PUMP GROUND CONTINUITY
Page 1716 of 2490
Measure t
he resistance between relay socket pin 5 and
ground BT020L.
1
I s
the resistance < 10OHM?
Yes GO to B6
No GO to B10
B6: CHECK FUEL
PUMP DRAWN CURRENT
•
NOTE
: With EM013 disconnected this test will cause the pump to operate continuously. Do not exceed 10 sec running.
•
NOTE: Do not replace relay.