Fuel Pump: Service and Repair

Fuel Pump Module









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.

WARNING: 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.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction 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.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Release the fuel system pressure.

2. Disconnect the battery ground cable.

3. Remove the Fuel Pump (FP) module access cover.

4. NOTE: Clean the FP (Fuel Pump) module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP (Fuel Pump) module electrical connector.


5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the fuel tube-to-FP (Fuel Pump) module quick connect coupling.

6. Disconnect the fuel tank filler pipe recirculation tube-to-FP (Fuel Pump) module quick connect coupling.

7. NOTE: For initial draining on vehicles with a full tank of fuel, it is required to remove the fuel through the fuel tank filler pipe recirculation tube port on the FP (Fuel Pump) module.
Connect the Fuel Storage Tanker hose to the fuel tank filler pipe recirculation tube port on the FP (Fuel Pump) module and remove approximately one-fourth of the fuel from a completely full tank (approximately 4 gallons), lowering the fuel level below the FP (Fuel Pump) module mounting flange.






8. NOTICE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the Fuel Pump (FP) module when removing the lock ring.

NOTE: When installing the FP (Fuel Pump) module, install a new O-ring seal.
Install the Fuel Tank Sender Unit Wrench and remove the FP (Fuel Pump) module lock ring.






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

NOTE: Some residual fuel may remain in the FP (Fuel Pump) module. Carefully drain into a suitable container.
Completely remove the FP (Fuel Pump) module from the fuel tank.


10. NOTE: Inspect the surfaces of the FP (Fuel Pump) 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 (Fuel Pump) module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove and discard the FP (Fuel Pump) module O-ring seal.


11. NOTE: Make sure to install a new FP (Fuel Pump) module O-ring seal.
To install, reverse the removal procedure.

- Make sure the alignment tabs on the FP (Fuel Pump) module and the fuel tank meet prior to tightening the FP (Fuel Pump) module lock ring.

- Tighten the FP (Fuel Pump) lock ring until it meets the stop tabs on the fuel tank.