Fuel Pump: Service and Repair

FUEL PUMP MODULE

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

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

1. Drain fuel tank and remove tank. Refer to the Fuel Tank Removal/Installation section of this group.
2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.

Fig.14 Top View Of Fuel Tank And Fuel Pump Module:

Fig.15 Lockout Removal/Installation - Typical:

3. The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 14). Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 15). The fuel pump module will spring up when locknut is removed.
4. Remove module from fuel tank.

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

CAUTION: Whenever the fuel pump module is serviced, the 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.
3. Apply clean water to locknut threads.
4. Position locknut over top of fuel pump module.

Fig.2 Fuel Filter/Fuel Pressure Regulator:

5. Rotate module until arrow (Fig. 2) 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 to 10 o'clock position.
9. Install fuel tank. Refer to Fuel Tank Installation in this section.