Fuel Pump: Service and Repair

Fuel Pump Module

Removal

WARNING: 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.

WARNING: Place the vehicle in a well ventilated, quarantined area and arrange ' No Smoking/Petrol Fumes' signs about the vehicle.

WARNING: 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.

WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
1 Remove the cover and disconnect the battery ground cable. For additional information, refer to Specifications [1][2]Battery
2
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.
3 With assistance, remove the fuel tank. For additional information, refer to Fuel Tank Removal and Replacement
4 Remove the fuel pump and sender cover locking ring.
- Remove the 6 nuts.
5 Remove the fuel pump and sender cover.
- Disconnect the electrical connector.
- Disconnect the 2 fuel lines.




6 Remove and discard the seal.




7
WARNING: The fuel tank is manufactured from stainless steel. Hand and arm protection must be used when removing parts from the inside of the tank, to prevent any injury.
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
Remove the fuel pump module.
- Rotate the pump module counter-clockwise.
- Disconnect the 2 fuel lines.
- Disconnect the electrical connector.




8
NOTE:
Do not disassemble further if the component is removed for access only.
Remove the fuel level sender unit.
- Carefully release the 2 clips.

Installation
1 Install the fuel level sender unit.
2
WARNING: The fuel tank is manufactured from stainless steel. Hand and arm protection must be used when removing parts from the inside of the tank, to prevent any injury.
WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
Install the fuel pump module.
- Connect the hoses.
- Connect and secure the electrical connector.
3 Install the new O-ring seals.
- Clean the components mating faces.
4 Install the fuel pump and sender cover.
- Disconnect the electrical connector.
- Disconnect the 2 fuel lines.
5 Install the fuel pump and sender cover locking ring.
- Tighten the nut to 10 Nm (7 lb.ft).
6 With assistance, install the fuel tank. For additional information, refer to Fuel Tank Removal and Replacement
7 Connect the battery ground cable and install the cover. For additional information, refer to Specifications [1][2]Battery