Fuel Gauge Sender: Service and Repair

Fuel Pump Module

Special Service Tools










Removal

NOTE:
- Non federal market vehicles, refer to steps 1 to 8.
- Federal market vehicles, refer to steps 9 to 19.

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 vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

NOTE:
- Non federal market vehicles, refer to steps 1 to 8.
- Federal market vehicles, refer to steps 9 to 19.

1. Remove the fuel transfer pump.

NOTE: Non federal market vehicles only.







2. Disconnect the electrical connector.

NOTE: Non federal market vehicles only.







3. Detach the electrical connector.

NOTE: Non federal market vehicles only.







4. Disconnect the fuel supply pipe.

NOTE: Non federal market vehicles only.







5. Using the special tool, remove the locking ring.

NOTE:
- Non federal market vehicles only.
- Note the orientation of the fuel pump module before removal.







6. Guide the fuel pump module through the aperture.

CAUTION: Make sure the float or arm are not damaged while removing the fuel pump module.

NOTE: Non federal market vehicles only.







7. Guide the cross over pipes through the aperture.

CAUTION: Make sure damage to the fuel cross over pipes does not occur.

NOTE: Non federal market vehicles only.







8. Remove the fuel pump module and cross over pipes.
- Remove and discard the O-ring seal.


NOTE: Non federal market vehicles only.

9. Remove the fuel tank.

NOTE: Federal market vehicles only.







10. Remove the fuel supply pipe.


NOTE: Federal market vehicles only.







11. Disconnect the electrical connector.

NOTE: Federal market vehicles only.







12 Using the special tool, remove the locking ring.

NOTE:
- Federal market vehicles only.
- Note the orientation of the fuel pump module before removal.







13. Detach the fuel pump module flange from the fuel pump module base.

NOTE: Federal market vehicles only.







14. Disconnect the electrical connector.

NOTE: Federal market vehicles only.







15. Disconnect the electrical connector.

NOTE: Federal market vehicles only.







16. Detach the fuel cross over pipe from the fuel pump module base.







17. Disconnect the electrical connector.

NOTE: Federal market vehicles only.







18. Disconnect the fuel cross over pipe from the fuel pump module base.

NOTE: Federal market vehicles only.







19. Remove the fuel pump module.
- Remove the fuel pump module base from the fuel tank.

CAUTION: Make sure the float or arm are not damaged while removing the fuel pump module.

NOTE: Federal market vehicles only.

Installation
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 vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury. This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

NOTE:
- Federal market vehicles, refer to step 1.
- Non federal market vehicles, refer to step 2.







1. To install, reverse the removal procedure.
- Install a new O-ring seal.
- Tighten to 120 Nm.

CAUTION: Make sure the float or arm are not damaged while installing the fuel pump module.

NOTE:
- Federal market vehicles only.
- Make sure the fuel pump module is correctly orientated.







2. install, reverse the removal procedure.
- Install a new O-ring seal.
- Tighten to 70 Nm.

CAUTION:
- Make sure the float or arm are not damaged while installing the fuel pump module.
- Make sure the fuel cross over pipes are not damaged while installing the fuel pump module.

NOTE:
- Non federal market vehicles only.
- Make sure the fuel pump module is correctly orientated.