Fuel Pump: Service and Repair

FUEL PUMP MODULE REMOVAL

Fuel Hose Tank Clips:

WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component.

1. Release fuel system pressure.
2. Fuel tank must be removed prior to fuel pump service.
3. Unclip the fuel drain hose and fuel vapor hose from the fuel tank clips.

Fuel Pump Band Clamp Removal/Installation:

4. Remove the fuel pump module clamp and remove fuel pump module from fuel tank.
5. Discard flat rubber gasket.

FUEL GAUGE SENDING UNIT REMOVAL

Fuel Level Sending Unit:

1. Remove the two sending unit mounting screws.
2. Disconnect the electrical terminals to the sending unit.

FUEL GAUGE SENDING UNIT INSTALLATION

1. Connect the electrical terminals to the sending unit.
2. Install and tighten the two mounting screws.

FUEL PUMP MODULE INSTALLATION

Fuel Pump Alignment:

1. Wipe seal area of tank clean, and install a new seal on tank.
2. Position fuel pump module in tank so that the arrow on the module is in between the two molded lines on the fuel tank.
3. Compress the module spring and install the module band clamp. Torque the band clamp to 40 in-lbs (4-5 Nm).
4. Clip the fuel drain and fuel vapor hoses to the fuel tank.
5. Install fuel tank assembly.

NOTE: ASD and fuel pump relays remain energized for 7 minutes during the following test, unless the test is stopped or the ignition switch is turned to the OFF position.

6. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system.
7. Check for leaks.