Fuel Tank Pump Module Replacement

REMOVAL PROCEDURE

CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.




1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
4. Remove the fuel tank.




5. Remove the fuel sender assembly.




6. Note the position of the fuel strainer (2) on the fuel sender.
7. Support the fuel sender assembly with one hand and grasp the strainer (2) with the other hand.
8. Pull the strainer off the fuel sender. Discard the strainer after inspection.
9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
10. Disconnect the fuel pump electrical connector (5).
11. Remove the electrical connector retaining clip (6) from the fuel level sensor.
12. Disconnect the sensor electrical connector (7) from under the fuel sender cover.
13. Remove the fuel level sensor retaining clip (4).
14. Squeeze the locking tangs and remove the fuel level sensor (3).
15. Remove the fuel pressure sensor (1).

INSTALLATION PROCEDURE




1. Install the fuel pressure sensor (1).
2. Install the fuel level sensor (3).
3. Install the sensor retaining clip (4).
4. Connect the electrical connector (7) to the fuel level sensor.
5. Connect the electrical connector retaining clip (6) to the fuel level sensor.
6. Connect the fuel pump electrical connector (5).

IMPORTANT: Always install a new fuel strainer when replacing the fuel tank fuel pump module.

7. Install a new fuel strainer (2) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.




8. Install the fuel sender assembly.




9. Install the fuel tank.
10. Refill the fuel tank.
11. Install the fuel filler cap.
12. Connect the negative battery cable.
13. Inspect for leaks.
13.1. Turn the ignition ON for 2 seconds.
13.2. Turn the ignition OFF for 10 seconds.
13.3. Turn the ignition ON.
13.4. Inspect for fuel leaks.