Fuel Pump Module - Steel Fuel Tank

Fuel Pump Module - Steel Fuel Tank

NOTE: Aft-of-axle fuel tank shown, auxiliary fuel tank similar.

NOTE: This procedure is for gasoline applications only.











Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

NOTE: This procedure is for gasoline applications only.

1. NOTE: The fuel tank must be drained completely. Upon removal of the Fuel Pump (FP) module, the tank must be inspected for contamination.

Remove the fuel tank. For additional information, refer to Fuel Tank - Aft-of-Axle Fuel Tank - Aft-Of-Axle or Fuel Tank - Auxiliary Fuel Tank - Auxiliary.

2. NOTICE: Clean the fuel tank of any dirt or foreign material before servicing the Fuel Pump (FP) module. In extreme dirt or dusty conditions it may be necessary to wash the fuel tank using a water hose. Before removing the FP module, make sure that there is no residual dirt or foreign material around the FP module flange. If dirt or foreign material enter the fuel tank, damage to the FP module or other fuel system components may occur.

Clean the area around the FP mounting flange.

3. NOTE: Mark the orientation of the FP module on the fuel tank to aid in installation.

Remove the 6 bolts from the FP module.
- To install, tighten to 10 Nm (89 lb-in).

4. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

Completely remove the FP module from the fuel tank.

5. NOTE: Inspect the surfaces of the FP module flange and fuel tank gasket contact surfaces. Do not polish or adjust the gasket contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the gasket contact area is bent, scratched or corroded or fuel leakage could occur.

NOTE: Make sure to install a new FP module gasket or fuel leakage could occur.

Remove and discard the FP module gasket.

Installation

1. Install a new FP module gasket.

2. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

NOTE: Check the FP module orientation during installation so that the supply tube is positioned away from the float rod.

Install the FP module into the fuel tank.

3. Rotate the FP module clockwise until the alignment marks on the FP module and fuel tank meet and then install the 6 bolts.
- Tighten to 10 Nm (89 lb-in).

4. Install the fuel tank. For additional information, refer to Fuel Tank - Aft-of-Axle Fuel Tank - Aft-Of-Axle or Fuel Tank - Auxiliary Fuel Tank - Auxiliary.