Fuel Pump: Service and Repair
FUEL PUMP MODULEFront Wheel Drive (FWD) Vehicle (Part 1):
Front Wheel Drive (FWD) Vehicle (Part 2):
All Wheel Drive (AWD) Vehicle (Part 1):
All Wheel Drive (AWD) Vehicle (Part 2):
Exploded View
Special Tool(s):
Special Tool(s)
Removal and 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 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 personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.
All vehicles
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Release the fuel tank filler cap and position aside.
4. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
5. Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel remaining in the fuel tank filler pipe.
6. Remove the rear seat.
7. Position the carpet and/or any insulation covering the fuel pump (FP) module access cover aside.
8. Remove the 4 screws and the FP module access cover.
9. Disconnect the FP module electrical connector.
10. Disconnect the fuel tank supply tube-to-FP module quick connect coupling.
11. CAUTION: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the fuel pump (FP) module from the vehicle to avoid fuel spillage inside the vehicle.
Using the special tool, remove the FP module lock ring retainer.
All wheel drive (AWD) vehicles
12. CAUTION: The fuel pump (FP) module must be handled carefully to avoid damage to the FP module and/or float arm.
Carefully lift the FP module out of the fuel tank enough to access and disconnect the fuel tank crossover tube-to-FP module quick connect coupling.
All vehicles
13. CAUTION: The fuel pump (FP) module will have residual fuel remaining internally, drain into a suitable container.
Completely remove the FP module from the fuel tank.
14. CAUTION:
- Inspect the mating surfaces of the fuel pump (FP) module flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new fuel pump (FP) module O-ring seal. Install a new lock ring if it is bent, damaged or corroded.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove the FP module O-ring seal.
15. NOTE: Make sure the alignment tab on the fuel pump (FP) module and the fuel tank meet before tightening the FP module lock ring.
To install, reverse the removal procedure.