Fuel Pump: Service and Repair

FUEL PUMP MODULE

Part 1:

Part 2:

Part 1:

Part 2:

Exploded View

Special Tool(s):

Special Tool(s)

Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.







3. Release the fuel tank filler cap and position aside.







4. Insert a suitable fuel drain hose into the fuel tank filler pipe until it reaches the fuel tank inlet tube.

5. CAUTION: The fuel pump (FP) module and fuel level sensor will be below the fuel level in the tank when the tank is full. Make sure to drain 1/8 of the fuel capacity through the filler pipe prior to removing the pumps or fuel spillage will occur.

NOTE: When draining a completely full fuel tank, this step will remove approximately 1/8 of fuel from the LH side of the fuel tank.

Attach the fuel storage tanker to the fuel drain hose and remove as much fuel as possible from the fuel tank filler pipe.

6. Remove the rear seat cushion.
7. Position any insulation padding covering the FP module access cover aside.







8. Remove the FP module access cover and position aside.







9. NOTE: 4.0L and 4.6L FP modules shown, 5.4L FP module similar.

Disconnect the FP module electrical connector.







10. NOTE: Place absorbent pads in the general work area in case of fuel spillage.

Disconnect the rear fuel supply tube-to-FP module quick connect coupling.







11. Using the special tool, remove and discard the FP module retaining lock ring.

12. CAUTION: The FP module must be handled carefully to avoid damage to the float arm, filter and the convolute hoses.

Carefully lift the FP module out of the fuel tank enough to access the fuel crossover tube-to-FP module quick connect coupling.







13. Disconnect the fuel crossover tube-to-FP module quick connect coupling.
14. Completely remove the FP module from the fuel tank.
15. Remove the FP module O-ring seal.

Installation

1. CAUTION:
- Inspect the surfaces of the FP module mounting flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new FP module O-ring seal and lock ring.

NOTE:
- Prior to installing the FP module and O-ring seal, thoroughly clean any contaminants from FP module and fuel tank mounting flanges.
- To install, apply clean engine oil to the O-ring seal.

Install the FP module O-ring seal.

2. Position the FP module into the fuel tank.







3. Connect the fuel crossover tube-to-FP module quick connect coupling.







4. NOTE: Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.

Using the special tool, install the FP module and lock ring.
- Tighten the lock ring until it meets the stops on the fuel tank.







5. Connect the rear fuel supply tube-to-FP module quick connect coupling.







6. Connect the FP module electrical connector.







7. NOTE: Remove and discard the absorbent pads.

Install the FP module access cover.

8. Install any insulation padding covering the FP module.
9. Install the rear seat cushion.
10. Install the fuel tank filler cap.
11. Connect the battery ground cable.

12. NOTE: It may take more than one key cycle to pressurize the fuel system. Cycle the ignition key and wait 3 seconds to pressurize the fuel system.

Check for leaks before starting the engine.

13. Start the engine and check for leaks.