Fuel Pump: Service and Repair

REMOVAL

WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES. NEVER SMOKE WHILE SERVICING THE VEHICLE.

1. Remove fuel filler cap and perform Fuel System Pressure Release procedure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Raise vehicle and support.
5. Remove fuel tank, refer to the Fuel Tank Removal.
6. Clean top of tank to remove loose dirt and debris.
7. Mark the fuel pump location on the top of the fuel tank.


NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly.

8. Disconnect fuel filter lines from fuel pump module.

Fig.10 Fuel Pump Module Locknut:

9. Using Special Tool # 6856 Fuel Pump Module Ring Spanner, remove locknut to release pump module (Fig. 10).

WARNING: THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED. THE FUEL IN THE RESERVOIR MAY SPILL OUT WHEN THE MODULE IS REMOVED.

10. Remove fuel pump module and seal from tank. Discard seal.

INSTALLATION
1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module opening.

NOTE: The pump has to properly located to the tank for the fuel gauge to work properly.

2. Position fuel pump module in tank. Make sure the alignment marks line up on the fuel tank and pump module.

CAUTION: Over tightening the pump lock ring may result in a leak.

3. While holding the pump module in position, install locknut. Tighten locknut to 74.5 Nm (55 ft. lbs) torque using special tool # 6856.
4. Install fuel tank, refer to the Fuel Tank Installation.
5. Lower vehicle.
6. Install the negative battery cable.
7. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
8. Fill fuel tank with clean fuel. Use the DRBIII scan tool to pressurize the system and check for leaks.