Fuel Pump Module - Removal

ALL WHEEL DRIVE

MAIN FUEL PUMP MODULE

WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.





1. Perform the fuel system pressure release procedure Service and Repair.
2. Remove the negative battery cable.
3. Remove the rear seat.
4. Remove the main fuel pump module access cover.





5. Disconnect the electrical connector (2) from the main fuel pump module (1).
6. Disconnect the fuel line (3) from the main fuel pump module.






NOTE: Prior to removing the main fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

7. Position the lock-ring remover/installer 9340 into the notches on the outside edge of the lock-ring.
8. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9340.
9. Rotate the breaker bar counterclockwise and remove the lock-ring.






NOTE: The main fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.

10. Mark the main fuel pump module orientation.






WARNING: The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

NOTE: Do not spill fuel into the interior of the vehicle.

11. Raise the main fuel pump module out of fuel tank using caution not spill fuel inside the vehicle.





12. Tip the main fuel pump module and drain enough fuel from the main fuel pump module reservoir to gain access to the internal fuel line without spilling fuel into the interior of the vehicle.





13. Disconnect the internal fuel line from the main fuel pump module.





14. Remove the main fuel pump module from the fuel tank using caution not to bend the float arm.





15. Tip the main fuel pump module on its side to drain all remaining fuel from reservoir.





16. Remove and discard the rubber O-ring seal.

AUXILIARY FUEL PUMP MODULE

WARNING: Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.





1. Perform the fuel system pressure release procedure Service and Repair.
2. Remove the negative battery cable.
3. Remove the rear seat.
4. Remove the auxiliary fuel pump module access cover.





5. Disconnect the electrical connector (2) from the auxiliary fuel pump module.






NOTE: The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.

6. Mark the auxiliary fuel pump module orientation (1).






NOTE: Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.

7. Position the lock-ring remover/installer 9318 into the notches on the outside edge of the lock-ring.
8. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer 9318.
9. Rotate the breaker bar counterclockwise and remove the lock-ring.





10. Raise the auxiliary fuel pump module and disconnect the internal fuel line.
11. Remove the auxiliary fuel pump module from the fuel tank.





12. Remove and discard the rubber O-ring seal.