Fuel Pump: Service and Repair

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

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. THIS MAY RESULT IN PERSONAL INJURY OR DEATH.

1. Remove fuel filler cap and perform Fuel System Pressure Release procedure. Service and Repair
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.
6. Clean top of tank to remove loose dirt and debris.




7. Note the fuel pump location on the top of the fuel tank.

8. Disconnect fuel filter lines from fuel pump module.




9. Using Special Tool #9340, remove lock ring to release pump module.

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. USE CAUTION TO AVOID PERSONAL INJURY.




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.




2. Position fuel pump module in tank. Make sure the alignment tab line up on the fuel tank and pump module for Gas or Diesel fuel tanks.




3. While holding the pump module in position, install lock ring and use special tool #9340 to tighten lock ring.
4. Install fuel tank.
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 Scan Tool to pressurize the system and check for leaks.