Fuel Pump: Service and Repair

REMOVAL
The fuel pump module is divided into 2 sections, upper and lower. To service the check (control) valve, replace only the upper section. To service the fuel gauge sending unit, remove the upper section. To service the electric fuel pump, fuel pressure regulator or primary inlet filter, remove both sections and replace lower section.

Fuel tank removal will not be necessary for fuel pump module removal. Access is from rear cargo area.

1. Four cargo holdown clamps are located inside the vehicle on the floor of the rear cargo area. Remove the 2 rearward mounted clamps by drilling out the clamp rivets.

Fig.25 Access Plate:

2. Fold carpeting forward to gain access to fuel pump module access plate.
3. Remove 4 fuel pump module access plate nuts.
4. While applying heat from a heat gun, carefully pry up fuel pump module access plate. Take care not to bend plate.
5. Thoroughly clean area around top of pump module to prevent contaminants from entering fuel tank or fuel lines.

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.

6. Release fuel system pressure. Refer to Fuel System Pressure Release procedure.

Fig.26 Top Of Fuel Pump Module:

7. Disconnect 2 fuel lines at fuel pump module by pressing on 2 buttons at sides of fitting.
8. Disconnect electrical connector at top of fuel pump module by sliding red colored tab first to unlock, and push grey colored tab down for removal.
9. Disconnect ORVR hose clamp and hose at pump module fitting.
10. Remove module lockring using a brass drift and hammer (counter-clockwise).
11. Carefully lift upper section of pump module from fuel tank exposing connections (lift upper section from tank very slowly until rubber gasket can be retained. If not, gasket will fall into fuel tank.)

Fig.27 Fuel Pressure Regulator/Sending Unit Electrical Connector:

a. Disconnect electrical connector at bottom of upper pump module section.
b. Disconnect fuel pressure regulator at bottom of upper pump module section. Press on 2 locking tabs.
c. Disconnect fuel return line at bottom of upper pump module section. Press on 2 locking tabs.

Fig.28 Upper Section - Fuel Pump Module:

d. Remove upper section of pump module from fuel tank.

12. Using an approved gas holding tank, drain fuel tank through pump module opening. If check (control) valve, or, only upper section of pump module is being serviced, tank draining is not necessary. If any other fuel pump module component is being serviced, the tank must be completely drained to the bottom.

13. To remove lower section of pump module from fuel tank:

Fig.29 Lower Section - Fuel Pump Module:

a. Using finger pressure, push on plastic release tab while sliding lock tab upward.

Fig.30 Fuel Pump Module Guides (In Fuel Tank):

b. The sides of pump module are equipped with tension springs. These springs hold module to bottom of fuel tank into 2 formed guides. Release module assembly from these 2 guides by sliding toward right side of fuel tank.
c. Lift assembly from fuel tank.

INSTALLATION

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

1. Position lower section of fuel pump module assembly into fuel tank.
2. The bottom of fuel tank has 2 formed guides. Lock module assembly into these 2 guides by sliding toward left side of fuel tank.
3. Push down on plastic tab to lock module to fuel tank guides.
4. Connect fuel supply line to bottom of upper pump module section.
5. Connect fuel pressure regulator to bottom of upper pump module section.
6. Connect electrical connector to bottom of upper pump module section.
7. Position pump module into fuel tank. Notch on module must be facing rear of tank.
8. Position lock ring to module. Tap lockring using a brass drift and hammer (clockwise) until rotated up to built-on stops.
9. Attach (snap on) 2 fuel filter fuel lines to top of fuel pump module.
10. Connect hoses/lines to ORVR components.
11. Fill fuel tank with fuel.
12. Start engine and check for fuel leaks.
13. Apply silicone sealant to bottom of fuel pump module metal access plate.
14. Install fuel pump module metal access plate and 4 nuts. Tighten nuts to 3 Nm (26 in. lbs.) torque.
15. Position carpet and install 2 new cargo clamp rivets into each cargo holdown clamp.