B. Replace Fuel Pump Module
NOTE:Fuel pump module replacement is only required on vehicles built from
August 1, 2004 through September 30, 2004 (MDH 080100 through 093023).
1. Release the fuel pressure from the fuel system using the following procedure:
a. Open the Power Distribution Center (PDC) cover located next to the battery (Figure 2).
b. Remove the fuel pump relay (Figure 2).
NOTE:
Refer to the PDC cover for fuel pump relay location.
c. Start the engine and allow it to run until the engine stalls.
2. Disconnect the negative battery cable.
3. Remove the fuel tank using the following procedure:
a. Drain the fuel from the fuel tank into a properly labeled GASOLINE safety container.
b. Raise vehicle on an appropriate hoist.
c. Loosen the exhaust pipe clamp and separate the exhaust system between the catalytic converter and the muffler.
d. Support the exhaust system with jack stands.
e. Remove muffler hanger rubber grommets.
f. Remove the center exhaust hanger rubber grommets.
g. With the help of an assistant, remove the rear portion of the exhaust system and set it on the floor.
h. Disconnect the fuel tank electrical connector located at the rear of the tank (Figure 3).
i. Disconnect the fuel line, EVAP line, and vapor recirculation tube located at the right front corner of the fuel tank (Figure 4).
j. For vehicles with all wheel drive, place alignment marks on the driveshaft where it attaches to the PTU and the rear axle.
k. For vehicles with all wheel drive, remove the front muffler heat shield.
l. For vehicles with all wheel drive, support driveshaft using jack stands.
m. For vehicles with all wheel drive, disconnect the rear end of the driveshaft.
n. For vehicles with all wheel drive, remove the center and rear driveshaft support/bearing bolts.
o. For vehicles with all wheel drive, disconnect the front end of the driveshaft.
p. For vehicles with all wheel drive, with the help of an assistant, lower the driveshaft assembly and set it aside.
q. Remove the left rear tire and wheel well plastic splash shield.
r. Remove the fuel filler tube from the rubber hose on the fuel tank.
s. Support the fuel tank with a transmission jack.
t. Remove the two fuel tank straps.
u. Lower the fuel tank.
4. Place the fuel tank on the floor.
5. Using a vacuum cleaner, remove any debris from the area around the driver's side fuel pump module lock ring (Figure 5).
6. Disconnect the vapor line and the electrical connector on the driver's side fuel pump module (Figure 5).
7. Using a brass punch and hammer, remove the driver's side fuel pump module lock ring (Figure 6).
NOTE:
Use a brass punch to rotate the lock ring 1/4 turn. Make contact only at the points shown in Figure 6.
8. Lift the fuel pump module top and disconnect the wire connector inside of the tank for the passenger side level sensor.
9. Remove the internal tank return fuel line from pump module. Use a small screwdriver to pry the lock tab back and tilt the hose to one side. Pry the lock tab back on other side to release the hose (Figure 7).
CAUTION:
Care should be taken to not crack/break the locking tabs or supply line fitting.
10. Remove the internal tank supply fuel line from top of the pump module. Use a small screwdriver to pry the lock tab back and tilt the hose to one side. Pry the lock tab back on other side to release the hose (Figure 8).
11. Tip the fuel pump module on its side to remove fuel from the reservoir.
12. Remove and discard the fuel pump module assembly and gasket.
13. Place the new fuel pump module gasket into position.
14. Install the new fuel pump module assembly into the fuel tank.
15. Connect the return fuel line first and then connect the supply fuel line to the new fuel pump module (Figure 7).
16. Connect the wires from the passenger side level sensor to the new pump module.
17. Install the fuel pump module top to fuel tank and then install the fuel pump module lock ring.
NOTE:
Use a brass punch to install the lock ring 1/4 turn.
18. Connect the vapor line and the electrical connector onto the driver's side fuel module (Figure 5).
19. Place the fuel tank back onto the transmission jack.
20. Raise the fuel tank into position and install the fuel tank straps. Tighten the mounting strap bolts to 40 ft. lbs. (54 N.m).
21. Install the fuel filler tube onto the rubber fuel tank fill hose and tighten the screw clamp securely.
22. Install the left rear wheel well plastic splash shield.
23. Install the tire/wheel assembly. Tighten the lug nuts to 100 ft. lbs. (135 N.m) and in the sequence shown in Figure 9.
24. For vehicles with all wheel drive, place the driveshaft in position with jack stands.
25. For vehicles with all wheel drive, align the marks made in Step 3j and install the front driveshaft onto the PTU. Install the front driveshaft bolts and tighten to 22 ft. lbs. (30 N.m).
26. For vehicles with all wheel drive, install the driveshaft center and rear support/bearing mounts. Tighten the support-to-body bolts to 40 ft. lbs. (54 N.m).
27. For vehicles with all wheel drive, align the marks made in Step 3j and install the driveshaft onto the rear axle. Then tighten the bolts to 40 ft.lbs (54 N.m).
28. Connect the fuel line, EVAP line and vapor recirculation tube located at the right front corner of the fuel tank (Figure 4).
29. Connect the fuel tank electrical connector located at the rear of the tank (Figure 3).
30. With the help of an assistant, place the rear portion of the exhaust system into position and support the exhaust system with jack stands.
31. Connect the inlet pipe of the front muffler to the outlet pipe of the catalytic converter. Tighten the exhaust pipe clamp to 40 ft. lbs. (54 N.m)
32. Install the center exhaust hanger rubber grommets.
33. Install the rear muffler rubber grommets onto the hangers (Figure 10).
34. Lower the vehicle from the hoist.
36. Fill the fuel tank with the fuel removed in Step 3a.
37. Install the fuel pump relay into the PDC and then close and latch the PDC cover.
38. Connect the negative battery cable.
39. Using the DRBIII scan tool to pressurize the fuel system, check for any fuel leaks.
40. Disconnect and remove the DRBIII from the vehicle.