Fuel Pump: Service and Repair
WARNINGS: Take the following actions when working with fuel in order to reduce the risk of fire and personal injury:- Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
- Provide forced air ventilation when working with fuel in enclosed areas where the fuel vapors can collect.
- Plug or cap any fuel system openings in order to limit fuel vapor formation. Clean up any spilled fuel immediately.
- Avoid sparks and any source of ignition.
- Install hazard warning signs in the work area.
CAUTIONS:
- Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
- For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel.
- Always replace the fuel sender seal when reinstalling the fuel sender assembly.
- The modular fuel sender assembly will spring-up when the snap ring is removed.
- Always maintain cleanliness when servicing fuel system components.
- Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
^ The fuel pipe connections
^ The hose connections
^ The areas surrounding the connections
REMOVAL PROCEDURE
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release Procedure.
2. Disconnect the negative battery cable.
3. Remove the spare tire cover, the jack, and the spare tire.
4. Remove the trunk liner.
5. Remove the (7) nuts retaining the fuel sender access panel.
6. Remove the fuel sender access panel.
7. Remove the [1][2]fuel tank pressure sensor electrical connector.
8. Remove the fuel sender electrical connector.
9. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal.
10. Remove the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Metal Collar).
11. Remove the fuel sender retaining snap ring.
12. Remove the modular fuel sender assembly.
13. Clean the fuel sender assembly O-ring sealing surfaces.
14. Inspect the fuel sender assembly O-ring sealing surfaces.
INSTALLATION PROCEDURE
CAUTIONS:
- Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.
- Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.
- Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.
1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Install the fuel sender assembly into the fuel tank.
3. Install the fuel sender assembly retaining snap ring.
4. Install the fuel sender electrical connector.
5. Install the [1][2]fuel tank pressure sensor electrical connector.
6. Install the quick-connect fittings at the fuel sender assembly. Refer to Quick Connect Fitting(s) Service (Metal Collar).
7. Install the negative battery cable.
8. Install the fuel filler cap.
9. Inspect for leaks.
a. Turn the ignition switch to the ON position for 2 seconds.
b. Turn the ignition switch to the OFF for 10 seconds.
c. Turn the ignition switch to the ON position again.
d. Visually inspect the fuel system for fuel leaks.
10. Install the fuel sender access panel.
11. Install the (7) nuts retaining the fuel sender access panel.
TIGHTEN
^ Fuel sender access panel nuts to 10 Nm (8 lb ft).
12. Install the trunk liner.
13. Install the spare tire, the jack, and the spare tire cover.