Fuel Pump Module Replacement

REMOVAL

CAUTION: To prevent damage to the float rod, the float and float rod must be removed from the pump module. This step must be done before the pump module is removed from the fuel tank.

1. Drain and remove fuel tank. Refer to Fuel Tank Removal/Installation.
2. Thoroughly clean area around pump module at top of tank.
3. Disconnect both fuel lines from pump module fittings.

Fuel Pump Module R/I:

4. The plastic fuel pump module locknut (lock-ring) is threaded onto fuel tank. Install Special Tool #6856 to locknut and remove locknut. The fuel pump module will spring up slightly after lock-nut is removed.

Float Rod Clip:

5. Pull module assembly up just a few inches to gain access to float support arm/rod (3). Be careful not to bend float support rod while removing pump module.

Float Rod Clip Removal:

6. Rotate clip (2) to release float rod (3) from fuel level sensor(1).

Float Rod Clip Removed:

7. Twist rod (3) slightly to remove from fuel level sensor Do not allow float assembly to fall into fuel tank.
8. While holding float rod, remove fuel pump module from fuel tank.
9. Remove float assembly from fuel tank.
10. Remove and discard rubber gasket (seal) from pump module.

INSTALLATION

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

1. Thoroughly clean locknut (lock-ring) and lock-nut threads at top of tank.
2. Position new gasket (seal) to fuel tank opening.
3. Position float rod assembly partially into fuel tank.
4. Position fuel pump module partially into fuel tank.

Float Rod Clip Installation:

5. Twist rod (3) into clip(2) on fuel level sensor(1).

Float Rod Clip Installation:

6. Rotate clip (2) to attach rod (3) to clip.
7. After attaching float assembly to fuel level sensor, carefully position fuel pump module into opening in fuel tank.
8. Position locknut over top of fuel pump module. Install locknut finger tight.

Align Pump Module:

9. Both fuel line fittings should be pointed to the right side of the vehicle Rotate and position alignment arrow towards right side of vehicle (if necessary) before tightening locknut This step must be performed to prevent the module's float from contacting the side of fuel tank.
10. Tighten locknut using Special Tool #6856 Refer to Torque Specifications