Fuel Pump Module
Fuel Pump Module
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the Fuel Pump (FP) module access cover.
4. NOTE: Clean the FP (Fuel Pump) module connections, couplings, flange surfaces and the immediate surrounding area of any dirt or foreign material.
Disconnect the FP (Fuel Pump) module electrical connector.
5. NOTE: Place absorbent toweling in the immediate surrounding area in case of fuel spillage.
Disconnect the fuel tank jumper tube-to-FP (Fuel Pump) module quick connect coupling.
6. Attach the Fuel Storage Tanker tube to the FP (Fuel Pump) module outlet fitting and remove approximately one-fourth (approximately 5 gallons) of the fuel from a completely full tank, lowering the fuel level below the FP (Fuel Pump) module mounting flange.
7. NOTE: Carefully install the Fuel Tank Sender Unit Wrench to avoid damaging the FP (Fuel Pump) module when removing the lock ring.
Using the Fuel Tank Sender Unit Wrench, remove the FP (Fuel Pump) module lock ring.
8. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
Carefully lift the FP (Fuel Pump) module out of the fuel tank allowing access and disconnect the internal fuel tube-to-FP (Fuel Pump) module quick connect coupling.
9. NOTE: Some residual fuel may remain in the FP (Fuel Pump) module. Carefully drain into a suitable container.
Completely remove the FP (Fuel Pump) module from the fuel tank.
10. NOTE: Inspect the surfaces of the FP (Fuel Pump) module 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 (Fuel Pump) module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove and discard the FP (Fuel Pump) module O-ring seal.
11. NOTE: Make sure to install a new FP (Fuel Pump) module O-ring seal.
NOTE: To install, apply clean engine oil to the O-ring seal.
To install, reverse the removal procedure.
- Make sure the alignment arrows on the FP (Fuel Pump) module and the fuel tank meet before tightening the FP (Fuel Pump) module lock ring.
- Tighten the FP (Fuel Pump) lock ring until it meets the stop tabs on the fuel tank.