Fuel Pump: Service and Repair

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. Drain fuel tank and remove tank, Refer to Fuel Tank Removal and Installation.
Service and Repair

2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.

Top View of Fuel Pump Module:

Locknut Removal/Installation-Typical:

3. The fuel pump module locknut is threaded onto fuel tank. Install Special Tool 6856 to fuel pump module locknut and remove locknut.

4. Remove module from fuel tank.

INSTALLATION

CAUTION: Whenever fuel pump module is serviced, module gasket must be replaced.

1. Thoroughly clean locknut threads and mating fuel tank threads. Use a soap/water solution. Do not use carburetor cleaner to clean threads.

2. Using new gasket, position fuel pump module into opening in fuel tank, Be sure rubber gasket remains in place.

3. Apply a small amount of clean engine oil to locknut threads.

4. Position locknut over top of fuel pump module. Tighten finger tight.

Top View of Fuel Pump Module:

5. Rotate module assembly until index arrow on pump module is aligned between index marks on fuel tank. This step must be followed to prevent float/float rod from contacting sides of fuel tank.

6. Install Special Tool 6856 to locknut.

7. Tighten locknut to 54 Nm (40 ft. lbs.) torque. While tightening locknut, be sure module has not rotated.

Top View of Fuel Pump Module:

8. Carefully rotate fuel filter/fuel pressure regulator until pointed towards drivers side of vehicle.

9. Install fuel tank. Refer to Fuel Tank Removal and Installation.
Service and Repair