Fuel Pump: Service and Repair

NOTE: The electric fuel pump is not serviceable. If the fuel pump or electrical wiring harness needs replacement, the complete fuel pump module must be replaced.

REMOVAL

Fig. 11 Fuel Pump Access Panel:

The trunk has an access cover in the floor panel for servicing the fuel pump module (Fig. 11).

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE REMOVING THE FUEL PUMP MODULE. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE.

1. Release fuel system pressure.
2. Disconnect negative cable from battery.
3. Open deck lid. Move trunk liner.
4. Remove access panel fasteners.

Fig. 12 Fuel Pump Access:

5. Remove access panel and gasket. Inspect gasket for damage. If necessary; replace gasket (Fig. 12).
6. Disconnect electrical connector from top of pump module.
7. Disconnect fuel tubes from fuel pump module. Refer to Quick-Connect Fittings.
8. Mark the fuel pump module and fuel tank for assembly of parts.
9. Using Special Tool # 6856 Fuel Pump Module Ring Spanner, remove locknut to release pump module.
10. Loosen locknut until fuel pump module rises up from tank.

WARNING: THE FUEL PUMP RESERVOIR MAY CONTAIN FUEL. DO NOT SPILL FUEL WHILE REMOVING THE MODULE.

11. To absorb possible fuel spillage, place shop towels around access opening. Without removing the module, tip it backwards to allow fuel in the reservoir to run down the side and back into the fuel tank.
12. The float arm of the level sensor catches on the inside of the tank while removing the module. Tilt the module to one side when removing from tank.
13. Remove fuel pump module and gasket from tank.
14. Drain remainder of fuel from reservoir before servicing the pump module.

INSTALLATION

Fig. 13 Fuel Pump Module Alignment Mark - Typical:

Fig. 14 Fuel Tank Alignment Mark - Typical:

The fuel pump module has a locator notch that has to fit into the fuel tank to correctly align the to parts (Fig. 13) and (Fig. 14). Align the marks to correctly position the pump module.
1. With a new gasket, insert the module straight into the tank to set float on bottom. Align marks on module and tank.
2. Seat module to tank by pushing the top down. Make sure the gasket does not slip over the outside or inside edge of the fuel tank lip. While holding module in seated position, place locknut over pump module and tighten locknut. Tighten locknut to 55 Nm (40 ft. lbs) torque. Do not over tighten the fuel pump locknut.
3. Install fuel tubes over fuel return and supply nipples on the module. Refer to Fuel Tubes and Quick Connect Fittings.
4. Attach electrical connector to fuel pump module.
5. Connect negative cable to battery.
6. Use DRB scan tool to pressurize fuel system. Check for leaks.
7. Install access cover and gasket. Tighten fasteners.
8. Install trunk liner.