Fuel Pump Module - Removal

REMOVAL

WARNING: The fuel system may be under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released.

1. Perform the fuel pressure release procedure as follows:
- For gas engines Service and Repair
- For diesel engine Service and Repair

NOTE: The fuel level of the vehicle must be below 5/8 of a tank before you remove the module lock-rings. If it is above that level you can spill fuel in the vehicle.

2. Partially drain the fuel tank, perform the fuel tank draining procedure as follows:
- For gas engines . Procedures
- For diesel engine . Procedures

3. Disconnect the negative battery cable.




4. Push the rear lower seat cushion up and back and remove the seat cushion.





5. Fold back the foam pad covering the fuel pump module rubber access plugs.





6. Remove the left side fuel pump module rubber access plug.





7. Disconnect the electrical connector from the fuel pump module.






CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.

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

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





11. Raise the fuel pump module up enough to gain access to the lower connections.
12. Disconnect the electrical connectors from under the top of the fuel pump module.





13. Press the quick connect release tab (3) and remove the fuel supply line (1).
14. Disconnect the lower fuel pump module electrical connector (2).





15. Disconnect the fuel pump module fuel return lines (1,2).
16. Tip the fuel pump module on its side to drain the remaining fuel from the bottom reservoir and remove from vehicle.

NOTE: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.

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