Fuel Pump: Service and Repair
Fig 2 Fuel Line Retainers And Pump Connector Lock:
FUEL PUMP MODULE
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.
WARNING: The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
REMOVAL
1. Remove fuel filler cap and perform Fuel System Pressure Release procedure.
2. Disconnect negative cable from battery.
3. Insert fuel siphon hose into fuel filler neck and push it into the tank.
4. Drain fuel tank dry into holding tank or a properly labeled gasoline safety container.
5. Raise vehicle on hoist.
6. Use a transmission jack to support the fuel tank.
- Remove bolts from fuel tank straps.
- Lower tank slightly.
7. Clean area around fuel tank module and tank to keep dirt and foreign material out of tank.
8. Disconnect fuel lines from fuel pump module by depressing quick connect retainers with thumb and fore finger (Fig. 2).
9. Slide fuel pump module electrical connector lock to unlock.
Fig 3 Pump Module Connector Retainer And Lock:
10. Push down on connector retainer (Fig. 3) and pull connector off module.
Fig 4 Fuel Pump Module Lock Nut Removal:
11. Using Special Tool 6856, remove plastic locknut counterclockwise to release pump module (Fig. 4).
Fig 5:
12. Carefully remove pump module and O-ring from tank (Fig. 5).
13. Discard old O-ring.
INSTALLATION
1. Wipe seal area of tank clean and place a new 0-ring seal in position on pump.
2. Position fuel pump in tank with locknut.
3. Tighten locknut to 58 Nm (43 ft lb).
4. Connect fuel lines.
5. Plug in electrical connector.
- Slide connector lock into position.
6. Raise fuel tank install bolts into fuel tank straps and tighten.
7. Lower vehicle on hoist.
8. Connect negative cable from battery.
9. Fill fuel tank.
- Check for leaks.
10. Install fuel filler cap.
FUEL PRESSURE REGULATOR
Fig 18 Fuel Pressure Regulator:
The fuel pressure regulator is part of the fuel pump module (Fig. 18). Remove the fuel pump module from the fuel tank to access the fuel pressure regulator.
WARNING: Fuel system pressure must be released before servicing any fuel system component. Perform the fuel system pressure release procedure.
REMOVAL
1. Spread tangs on pressure regulator retainer (Fig. 18).
2. Pry fuel pressure regulator out of housing.
3. Ensure both upper and lower 0-rings were removed with regulator.
Fig 19 Fuel Pressure Regulator O-rings:
INSTALLATION
1. Lightly lubricate the 0-rings with clean engine oil and place them into opening in pump module (Fig. 19).
2. Push regulator into opening in pump module.
3. Fold tangs on regulator retainer over tabs on housing.
FUEL PUMP INLET STRAINER
Fig 20 Inlet Strainer Removal:
REMOVAL
1. Remove fuel pump module. Refer to Fuel Pump Module Removal in this section.
2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer (Fig. 20).
3. Remove strainer 0-ring from the fuel pump reservoir body.
4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank.
INSTALLATION
1. Lubricate the strainer 0-ring with clean engine oil.
2. Insert strainer 0-ring into outlet of strainer so that it sits evenly on the step inside the outlet.
3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer.
4. Install fuel pump module. Refer to Fuel Pump Module Installation in this section.
FUEL LEVEL SENSOR
Fig 21 Fuel Pump/Level Sensor Electrical Connector:
REMOVAL
Remove fuel pump module. Refer to Fuel Pump Module.
1. Depress retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 21).
Fig 22 Wire Terminal Locking Wedge:
2. Pull off blue locking wedge (Fig. 22).
Fig 23 Wire Terminal Locking Finger:
3. Using a small screwdriver lift locking finger away from terminal and push terminal out of connector (Fig. 23).
Fig 24 Removing Wires From Connector:
4. Push level sensor signal and ground terminals out of the connector (Fig. 24).
Fig 25 Loosening Level Sensor:
5. Insert a screwdriver between the fuel pump module and the top of the level sensor housing (Fig. 25). Push level sensor down slightly.
Fig 26 Level Sensor Removal/Installation:
6. Slide level sensor wires through opening fuel pump module (Fig. 26).
7. Slide level sensor out of installation channel in module.
Fig 27 Groove In Back Side Of Level Sensor:
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
2. Wrap wires into groove in back of level sensor (Fig. 27).
Fig 28 Installation Channel:
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place (Fig. 28).
- Ensure tab at bottom of sensor locks in place.
4. Install level sensor wires in connector. Push the wires up through the connector and then pull them down until they lock in place.
- Ensure signal and ground wires are installed in the correct position.
5. Install locking wedge on connector.
6. Push connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module. Refer to Fuel Pump Module.