Fuel Pump Module - Removal
REMOVAL
Special Tools:
MAIN FUEL PUMP MODULE
WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.
WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.
1. Perform the fuel system pressure release procedure Service and Repair.
CAUTION: If the fuel pump module is not operating or the fuel level sending unit is not operating and the fuel level cannot be determined, the fuel tank must be removed prior to draining.
2. Perform the fuel tank draining procedure Procedures
3. Disconnect and isolate the negative battery cable (2).
4. Remove the fuel tank Fuel Tank - Removal.
NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around the fuel tank opening.
5. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the main fuel pump module lock ring (2).
6. Install a 1/2 inch drive breaker bar (3) onto the SAE Fuel Pump Lock Ring Wrench (1).
NOTE: The main fuel pump module will spring up slightly when lock ring is removed.
7. Rotate the breaker bar counterclockwise and remove the lock ring.
CAUTION: An indexing arrow is located on top of the main fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.
NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
8. Mark the main fuel pump module orientation.
CAUTION: Do not allow the float arm of the main fuel pump module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
9. Using caution not to bend the float arm (2), lift the main fuel pump module (3) out of the fuel tank enough to gain access to the auxiliary fuel pump module supply line connection (1) and disconnect the supply line.
10. Tip the main fuel pump module on its side to drain the remaining fuel from the reservoir and remove the main fuel pump module.
CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
11. Remove and discard the rubber O-ring seal.
AUXILIARY FUEL PUMP MODULE
WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.
WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.
1. Remove the main fuel pump module MAIN FUEL PUMP MODULE.
NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
2. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the auxiliary fuel pump module lock ring (2).
3. Install a 1/2 inch drive breaker bar (3) onto the SAE Fuel Pump Lock Ring Wrench (1).
NOTE: The auxiliary fuel pump module will spring up slightly when the lock ring is removed.
4. Rotate the breaker bar counterclockwise and remove the lock ring.
CAUTION: An indexing arrow is located on top of the auxiliary fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.
NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
5. Mark the auxiliary fuel pump module orientation.
CAUTION: Do not allow the float arm of the auxiliary fuel pump module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
6. Using caution not to bend the float arm (2), lift the auxiliary fuel pump module (1) and the auxiliary fuel pump module supply line (3) out of the fuel tank as an assembly.
CAUTION: Whenever the auxiliary fuel pump module is serviced, the rubber O-ring seal must be replaced.
7. Remove and discard the rubber O-ring seal.