Service Procedure

1. Remove the fuel filler cap.

2 Insert a siphon hose into the fuel filler tube and drain the fuel into an approved gasoline holding tank until the fuel level in the tank is at or below 1/4 full.

NOTE:
To ease siphon hose insertion into the fuel tank, use a piece of 1/4" I.D. Tygon tubing to drain the fuel tank.

3. Remove the cover from the power distribution center (PDC).

4. Remove the fuel pump relay from the PDC.

5. Start the vehicle and run it until it runs out of fuel; then crank the engine for an additional 10 seconds. Turn the key to the OFF position.

6. Install the fuel pump relay and PDC cover.

7. With the ignition key in the OFF position, disconnect the negative battery cable.

NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure.

8. Raise the vehicle on an appropriate hoist.

9. Support the fuel tank using a transmission jack.

10. Remove the two (2) inboard fuel tank strap bolts.

11. Lower the inboard side of the fuel tank about 3" to allow access to the fuel pump module.

12. Using a shop rag, clean any dirt and debris from around the fuel pump module area.








13. Slide the fuel pump module electrical connector lock to the unlocked position (Figure 1). Push down on the connector retainer and then pull the connector from the module (Figure 2).

14. Disconnect both fuel line quick connects from the fuel pump module (Figure 1).

15. Clean any excess gasoline and/or dirt from the fuel pump module flange.





16. Using Miller Special Tool No.8269, remove the lock nut (Figure 3).

17. Clean any excess gasoline and/or dirt from the fuel pump module flange.

18. Remove the fuel pump module and then remove and discard the fuel pump module seal.

19. Install the new fuel pump module. Make sure that the locating tab on the fuel pump module is aligned with the notch in the fuel tank (Figure 5).

IMPORTANT:
Do NOT install the new lock nut SEAL at this time or the lock nut may not be properly tightened and fuel leakage may occur.

20. Using Miller Special Tool No.8269, tighten the fuel pump module lock nut to 20 FL-lbs (27 Nm) (Figure 3).

IMPORTANT:
The lock nut MUST be tightened using Miller Special Tool No.8269. Do not over-tighten the lock nut. To ensure a correct torque measurement, the torque wrench must be installed in line with the special tool handle.





21. With a paint marker or similar tool, mark the top of the fuel pump module and the lock nut to indicate the location of the arrow on the lock nut after the lock nut has been tightened without having the seal installed (Figure 4).

22. Using Miller Special Tool No.8269, remove the lock nut (Figure 3).





23. Slightly raise the fuel pump module and carefully install the NEW fuel pump module seal (Figure 5). Use care to not stretch the new seal when installing it over the module.

CAUTION:
Make sure that the new seal is fully seated on the fuel pump module sealing surface.

24. Install the lock nut. Make sure that the locating tab on the fuel pump module is aligned with the notch in the fuel tank (Figure 5).

25. Using Miller Special Tool No.8269, tighten the lock nut to 35 FL-lbs (47.5 Nm) (Figure 3).

IMPORTANT:
The lock nut MUST be tightened using Miller Special Tool No.8269. Do not over-tighten the lock nut. To ensure a correct torque measurement, the torque wrench must be installed in line with the special tool handle.

26. Check the position of the arrow on the lock nut relative to the mark made on the fuel pump module in Step 21 above.

^ If the lock nut has been tightened such that the arrow is at or beyond the mark on the fuel pump module, continue with Step 27.

^ If the lock nut has been tightened such that the arrow has not reached the mark on the fuel pump module, tighten the lock nut further until the arrow is aligned with the mark.

27. Connect both fuel lines to the fuel pump module (Figure 1). Push the connectors on to the nipples until they are seated and then pull back and push on again to assure that the connectors are secure.

NOTE:
Wipe any excess fuel from the fuel pump module.

28. Connect the fuel pump module electrical connector. Be sure to slide the retainer into the locked position (Figure 1).

29. Raise the fuel tank into position and install the inboard fuel tank strap bolts. Torque the strap bolts to 40 FL-lbs (54 Nm).

30. Remove the tank support and lower the vehicle.

31. Refill the fuel tank.

32. Connect the negative battery cable.

33. Start the engine and check for any fuel leaks.