Fuel Pump: Service and Repair

FUEL PUMP MODULE

REMOVAL
1. Release the fuel pressure.
2. Disconnect negative battery cable.

NOTE: The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that you can spill fuel in the vehicle.




3. Drain partial fuel from fuel tank through the filler tube. Use a hard nylon tube, with a 30° cut on the end, to push the check valve open to drain fuel from tank.




4. Remove the rear lower seat cushion.




5. Push seat back and up to remove seat cushion.




6. Fold back the foam pad covering access cover for modules.




7. Disconnect the electrical connector from left side module.
8. Mark the module orientation.




9. Use special tool #9340 to remove left side module lock ring.




10. Drain fuel from left side of fuel tank. Lift module up enough to push hose into tank and drain. Do not spill fuel in interior of vehicle.




11. Disconnect the electrical connectors from the module top.
12. Remove the module top half.




13. The module fuel level sending card (1). The fuel return lines (2). The fuel supply line (3).




14. Fuel line release tab, press in the tab and pull up on fuel line.




15. Remove fuel line.




16. Remove fuel return line from lower module. Line unsnap from module.




17. Return line removed.




18. Tip module on its side to drain remaining fuel from reservoir and remove module from vehicle.

INSTALLATION




1. Install pump module into tank.
2. Connect fuel return lines to module.




3. Lines connected.




4. Connect fuel supply line to module and make sure it is locked in place.




5. Connect electrical connectors to bottom of module top, Install module top to module bottom.




6. Install module and align marks on the module for proper orientation.




7. Install module lock-ring.
8. Use special tool #9340 to tighten left side module lock ring.
9. Connect the electrical connector to left side module.




10. Install plastic access cover.




11. Fold the foam pad covering access cover for modules back into place.




12. Install rear lower seat cushion




13. Rear lower seat cushion installed.




14. Fill fuel tank.
15. Connect negative battery cable.
16. Fill fuel tank. Use the scan tool to pressurize the fuel system. Check for leaks.