Fuel Pump: Service and Repair

REMOVAL
Fuel tank removal will be necessary for fuel pump module removal.

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

1. Drain fuel tank and remove tank. Refer to the Fuel Tank Removal/Installation.
2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.
3. Disconnect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.

Fig.15 Top View Of Fuel Tank And Fuel Pump Module:

Fig.16 Locknut Removal/Installation:

4. The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 15). Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 16). The fuel pump module will spring up when locknut is removed.
5. 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 a new gasket, position gasket and fuel pump module into opening in fuel tank.
3. Apply clean water to gasket and locknut threads.
4. Position locknut over top of fuel pump module.
5. Rotate module until molded arrow (Fig. 15) is pointed toward front of vehicle (12 O'clock position).
This step must be done to prevent float/float rod assembly from contacting sides of fuel tank.
6. Install Special Tool 6856 to locknut.
7. Tighten locknut to 74 Nm (55 ft. lbs.) torque.
8. Rotate fuel filter/fuel pressure regulator until its fitting is pointed toward front of vehicle (12 O'clock position).
9. Connect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.
10. Install fuel tank.