Fuel Transfer Unit - VIN Range: N52048->N99999
Fuel Transfer Unit - 4.2L/2.5L/3.0L, VIN Range: N52048->N99999
Special Service Tools
Removal
WARNING:
- Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.
- Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
- The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. Failure to follow these instructions may result in personal injury.
- After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.
- This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
- If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.
- If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention.
- Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
NOTE:
- Federal market vehicles, refer to steps 14 and 25.
- Non federal market vehicles, refer to steps 15 and 26.
NOTE: All vehicles
1. Open the fuel tank filler pipe flap.
2. Disconnect the battery ground cable.
3. Detach the fuel tank filler pipe cap.
4. Release the pressure in the fuel system.
5. Drain the fuel system.
6. Remove the rear seat cushion.
7. Detach and reposition the door opening weatherstrip.
8. Remove the scuff plate trim panel.
9. Detach and reposition the floor covering.
10. Detach and reposition the rear seat cushion insulation.
11. Remove the floor aperture cover.
12. Disconnect the fuel pump module electrical connector.
- Detach the fuel pump module wiring harness from the retaining bracket.
13. Disconnect the fuel pump module quick release coupling.
NOTE: Federal market vehicles only.
14. Remove the fuel pump module locking ring.
- Remove and discard the O-ring seal.
NOTE: Non federal market vehicles only.
15. Using the special tool,remove the fuel pump module locking ring.
- Remove and discard the O-ring seal.
NOTE: All vehicles.
16. Disconnect the fuel transfer unit transfer feed tube.
17. Disconnect the left-hand fuel sender gauge electrical connector.
18. Disconnect the fuel transfer unit transfer return tube.
19. Release the fuel pump module.
- Press down and rotate the fuel pump module counter-clockwise.
20. Detach and reposition the door opening weatherstrip.
21. Remove the scuff plate trim panel.
22. Detach and reposition the floor covering.
23. Detach and reposition the rear seat cushion insulation.
24. Remove the floor aperture cover.
NOTE: Federal market vehicles only.
25. Remove the fuel transfer unit locking ring.
NOTE: Non federal market vehicles only.
26. Using the special tool, remove the fuel transfer unit locking ring.
CAUTION: Make sure no damage occurs to the fuel level float.
NOTE: All vehicles.
27. Remove the fuel transfer unit.
- Press down and rotate the base of the fuel transfer unit counter-clockwise.
- Remove and discard the O-ring seal.
Installation
NOTE:
- Federal market vehicles, refer to steps 3 and 14.
- Non federal market vehicles, refer to steps 2 and 13.
CAUTION: Make sure no damage occurs to the fuel level float.
NOTE: All vehicles.
1. Install the fuel transfer unit.
- Press down and rotate the base of the fuel transfer unit clockwise
- Install a new O-ring seal.
NOTE: Non federal market vehicles only.
2. Using the special tool, install the fuel transfer unit locking ring.
- Tighten to 60 Nm.
NOTE: Federal market vehicles only.
3. Install the fuel transfer unit locking ring.
- Tighten to 4 Nm.
NOTE: All vehicles.
4. Install the floor aperture cover.
5. Attach the rear seat cushion insulation.
6. Attach the floor covering.
7. Install the scuff plate trim panel.
8. Attach the door opening weatherstrip.
CAUTION:
- On vehicles with supercharger make sure the arrow on the fuel pump module and the 'SC' marker on the fuel tank are aligned.
- On vehicles without supercharger make sure the arrow on the fuel transfer module and the 'NA' marker on the fuel tank are aligned.
9. Secure the fuel pump module.
- Press down and rotate the base of the fuel pump module clockwise.
10. Connect the fuel transfer unit transfer return tube.
- Make sure the coupling has latched onto the fuel pump module by pulling the tube after the connection has been made.
11. Connect the left-hand fuel sender gauge electrical connector.
12. Connect the fuel transfer unit transfer feed tube.
- Make sure the quick release coupling has latched onto the fuel pump module fuel tube by pulling the tube after the connection has been made.
NOTE: Non federal market vehicles only.
13. Using the special tool, install the fuel pump module locking ring.
- Install a new O-ring seal.
- Tighten to 60 Nm.
NOTE: Federal market vehicles only.
14. Install the fuel pump module locking ring.
- Tighten to 4 Nm.
NOTE: All vehicles.
15. Connect the fuel pump module quick release coupling.
- Make sure the quick release coupling has latched onto the fuel pump module fuel pipe by pulling the pipe after the connection has been made.
16. Connect the fuel pump module electrical connector.
- Attach the fuel pump module wiring harness to the retaining bracket.
17. Install the floor aperture cover.
18. Attach the rear seat cushion insulation.
19. Attach the floor covering.
20. Install the scuff plate trim panel.
21. Attach the door opening weatherstrip.
22. Install the rear seat cushion.
23. Attach the fuel tank filler pipe cap.
24. Connect the battery ground cable.
25. Close the fuel tank filler pipe flap.