Fuel Level Sensor: Service and Repair

Fuel Pump Module (19.45.03)

Removal

WARNING:
^ Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle.
^ 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.
^ Do not smoke or carry lighted tobacco or 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.
^ The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.

NOTE: The fuel pump module comprises of a rear fuel level sender, filter and a fuel pressure regulator. These components cannot be serviced separately.

1. Disconnect the battery ground cable.
2. Raise and support the vehicle.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

3. Remove the fuel tank.

4. Release the fuel pump module access flange.
^ Loosen the screw.
^ Remove the clamp.

CAUTION: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination.

NOTE: Note the fitted position.





5. Remove the fuel pump module access flange.
^ Disconnect the vent line.
^ Disconnect the fuel supply line.
^ Disconnect the 3 electrical connectors.
^ Remove and discard the seal.





6. Remove the fuel pump module.
^ Release the strap.
^ Release the fuel pressure regulator.
^ Disconnect the 2 fuel lines.





Installation
1. Install the fuel pump module.
^ Connect the fuel lines.
^ Secure with the strap.
^ Secure the fuel pressure regulator.
2. Install the fuel pump module access flange.
^ Clean the component mating faces.
^ Install a new seal.
^ Connect the 3 electrical connectors.
^ Connect the fuel supply line.
^ Connect the vent line.

3. Secure the fuel pump module access flange.
^ Install the clamp.
^ Tighten the screw to 4 Nm (3 lb.ft).

CAUTION: Make sure the seal is correctly fitted.

NOTE: Align to the position noted on removal.





4. Install the fuel tank.
5. Connect the battery ground cable.