Fuel Tank Unit: Service and Repair

FUEL PUMP MODULE REMOVAL/INSTALLATION






WARNING:
- Do not smoke or carry lighted tobacco or 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 components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel. Failure to follow these instructions may result in serious personal injury.
- The fuel in the tank may be pressurized. Remove the fuel tank cap slowly. If a hissing sound is heard, wait until the condition stops before removing the fuel tank filler cap. Failure to follow these instructions may result in serious personal injury.

1. Release the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE.
2. Release the fuel tank filler cap and position aside.




3. Insert the special tool into the fuel tank filler pipe until it opens the fuel tank level shutoff valve located at the inlet of the fuel tank.
4. Using the special tools, drain as much fuel as possible from the fuel tank and filler pipe, lowering the fuel level below the fuel pump (FP) mounting flange.

NOTE: Due to the internal design of the fuel tank components, slow fuel drainage may occur.

5. Remove the 4 screws and the fuel pump (FP) module access cover.
6. Disconnect the FP module electrical connector.

NOTE: Clean the FP module connection, couplings, mounting flange and the immediate surrounding area of any dirt or foreign material.

7. Disconnect the fuel supply tube and fuel vapor recirculation tube-to-FP module quick connect couplings. See QUICK RELEASE COUPLING - DOUBLE LOCKING.

NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spills.

8. Using a suitable FP lock ring remover, rotate the lock ring counterclockwise and remove the FP module.

CAUTION: The fuel pump (FP) module must be handled carefully to avoid damage to the float arm and the filter.

NOTE:
- Carefully remove the FP module lock ring and verify that enough fuel has been drained to avoid spillage.
- Drain any residual fuel in the FP module into a suitable container.

9. Remove and discard the FP module O-ring seal.

NOTE: Inspect the surfaces of the FP module flange and fuel tank seal contact surfaces. Do not polish or adjust the seal contact area of the FP module flange or fuel tank. Install a new FP module or fuel tank if the seal contact area is bent, scratched or corroded.

10. To install, reverse the removal procedure.

NOTE: Apply clean engine oil to the FP module O-ring seal.