Fuel Pump: Service and Repair
FUEL PUMP MODULEExploded View
Part 1:
Part 2:
Part 1:
Part 2:
Special Tool(s)
Special Tool(s):
Removal and Installation
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.
- 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- 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.
1. Release the fuel system pressure.
2. Release the fuel tank filler cap and position aside.
3. NOTE:
- When the fuel tank is completely full, this step will remove approximately 1/8 of the fuel from the fuel tank.
- The special tool must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank inlet, opening the safety valve allowing fuel tank drainage. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.
Insert the special tool into the fuel tank filler pipe.
- Attach the fuel storage tanker to the special tool and remove as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) module mounting flange.
4. Remove the rear seat cushion.
5. Remove the FP module access cover and position aside.
6. NOTE: Clean the FP module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP module electrical connector.
7. NOTE: Place absorbent pads in the general work area in case of fuel spillage.
Disconnect the rear fuel tube-to-FP module quick connect coupling.
8. Using the special tool, remove and discard the FP module lock ring.
9. CAUTION: The fuel pump (FP) module must be handled carefully to avoid damage to the float arm.
Carefully lift the FP module out of the fuel tank allowing access and disconnect the internal fuel tube-to-FP module quick connect coupling.
10. NOTE: Drain any residual fuel in the FP module into a suitable container.
Completely remove the FP module from the fuel tank.
11. NOTE:
- Inspect the surfaces of the FP module 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.
- To install, apply clean engine oil to the O-ring seal.
Remove and discard the FP module O-ring seal.
12. NOTE:
- Make sure to install a new FP module lock ring and O-ring seal.
- Make sure the alignment arrows on the FP module and the fuel tank meet before tightening the FP module lock ring.
To install, reverse the removal procedure.
- Tighten the FP module lock ring until it meets the stop tabs on the fuel tank.