Fuel Pump
FUEL PUMP MODULESpecial Tool(s):
Special Tool(s)
Removal and Installation
WARNING:
- Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited, resulting in possible 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 can result in personal injury.
- This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the fuel tank filler cap.
4. Insert the special tool into the filler neck.
5. NOTE: Insert the special tool until the stop contacts the guide tube. If the stop does not contact the guide tube, remove the hose and repeat the procedure.
Insert the chamfered end of the hose into the filler pipe through the guide tube.
6. CAUTION: The fuel pump (FP) module and fuel level sensor will be below the fuel level in the tank when the tank is full. Make sure to drain 1/8 of the fuel capacity through the filler pipe prior to removing the pumps or fuel spillage will occur.
Attach a suitable fuel recovery system to the hose and remove the fuel from the tank.
7. Remove the rear seat bottom and any insulation padding covering the FP module.
8. Remove the FP module access cover.
9. Disconnect the electrical connector and release the fuel tube quick connect coupling on the FP module.
10. Using the special tool, remove the FP module lock retaining ring.
11. Position the FP module askew and install the special tool and a suitable fuel recovery system.
12. Completely drain the FP side of the fuel tank.
13. Carefully lift the FP module out of the fuel tank allowing access to the quick connect coupling.
14. Disconnect the quick connect coupling from the bottom of the FP module.
15. CAUTION: The FP module must be removed and handled carefully to avoid damage to the float arm.
Completely remove the FP module from the fuel tank.
16. CAUTION:
- Inspect the surfaces of the FP module mounting flange and 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 FP module O-ring seal and lock ring.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove the fuel pump module O-ring seal.
17. To install, reverse the removal procedure.
- Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.