Service Procedure

1. Move both front seats to their full forward position.

2. Loosen the fuel filler cap.

3. Remove the rear seat lower cushion.





4. Remove the black plastic fuel pump module access cover (Figure 1).

5. Disconnect the fuel pump module electrical connector.





6. Remove the fuel pump module wiring harness rubber grommet from the floor pan opening and pull wiring from body opening (Figure 2).

NOTE:
The fuel pump module wiring harness rubber grommet must be removed to provide clearance for the removal of the fuel line extension in an upcoming step.

7. Remove and discard the fuel module electrical connector adapter (Figure 2).

8. Use the following procedure to release the fuel pressure from the fuel lines:

a. Start the engine and allow it to idle until it stalls.

b. Restart the engine three more times and allow it to idle each time until it stalls.

WARNING:
Failure to release the fuel pressure before
disconnecting the fuel line could cause fuel to spray inside the vehicle and possibly cause a fire.

9. Disconnect the negative battery cable.

10. Raise the vehicle on a hoist.

11. Remove the left rear underbody plastic splash shield to gain access to the fuel line extension quick connect fitting.





12. Disconnect the fuel line extension quick connect fitting where it meets the underbody fuel line bundle (Figure 3).

WARNING:
The fuel line will have some residual fuel left in the fuel line. Take appropriate precautions when disconnecting the fuel line.

13. Lower the vehicle from the hoist.

14. Disconnect the fuel line extension quick connect at the fuel pump module.

15. Remove and discard the fuel line extension.

16. Clean the top of the fuel module to prevent dirt from falling into the tank during removal.

17. Remove the fuel pump module lock ring using Special Tool 9340 (Figure 4).

18. Carefully remove the fuel pump module from fuel tank.

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

19. Remove and discard the original fuel pump module O-ring seal from
fuel tank.

20. Wipe the seal area of fuel tank clean and install a new O-ring seal onto the fuel tank.

21. Install the fuel pump module to the fuel tank.





22. Install the fuel pump module lock ring using special tool 9340
(Figure 4).





23. Install the new fuel line extension and connect it to the fuel pump module outlet fitting (Figure 5).

24. Lift the vehicle on a hoist.

25. Connect the fuel line extension quick connect fitting to the underbody fuel line bundle.

26. Install the left rear underbody plastic splash shield.

27. Lower the vehicle from the hoist.

28. Route the fuel pump module wiring harness through the floor pan opening and connect the electrical connector to the fuel pump module.

29. Insert the rubber fuel pump module wiring harness grommet into the floor pan opening.

30. Connect the negative battery cable.

31. Place the ignition key in the "RUN" position and check the fuel line extension quick connects for fuel leaks.

32. Place the ignition key in the "OFF" position.

33. Install the black plastic fuel pump module access cover.

34. Install the rear seat lower cushion.

35. Install the fuel filler cap.

36. Move both front seats to their original positions.

37. Reconfigure the Totally Integrated Power Module (TIPM) using the following procedure:

a. Connect a battery charger.

b. Connect the StarSCAN to the vehicle's data link connector.

c. Connect the ethernet cable to the StarSCAN and the dealer network.

d. Turn the ignition key to the "RUN" position and then turn on the StarSCAN.

e. From the "Home" screen, select "ECU View".

f. Select "TIPM/CGW Central Gateway".

g. Select "Misc. Functions".

h. Select "Restore Vehicle Configuration".

i. Press the blue "START" button.

j. Follow the StarSCAN screen prompts to complete the TIPM reconfiguration.

k. Continue with Step 38 of this procedure.

38. Clear any Diagnostic Trouble Codes (DTCs) using the following procedure:

a. From the "Home" screen, select "System View".

b. Select "All DTCs".

c. Press "Clear All Stored DTCs" if there are any DTCs shown on the list.

d. Turn the ignition key to the "OFF" position and remove the StarSCAN from the vehicle.

e. Disconnect and remove the battery charger.