Fuel Pump Module

FUEL PUMP MODULE

Special Tool(s):

Special Tool(s)







Removal

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in personal injuries.

1. Drain the fuel tank.

2. NOTE: The routing of the internal fuel crossover tubes is critical to correct fuel system operation. Note the routing of the internal fuel crossover hoses at this time.

Partially raise the fuel transfer pump and disconnect the internal fuel crossover tube quick connect couplings.
- Remove and discard the fuel transfer pump O-ring seal.

3. Disconnect the fuel pump module tube quick connect coupling from the fuel pump module and position aside.







4. CAUTION: Drain the remaining fuel from the delivery module into the fuel tank prior to removal.

Before removal, attach a non-conductive material to the crossover tubes. Then remove the fuel pump module and crossover tubes as an assembly, using the non-conductive material to pull the crossover lines through the gas tank.
- Remove and discard the fuel pump module O-ring seal.

Installation

1. NOTE: Install the fuel pump module and crossover tubes as an assembly.

Attaching the non-conductive material to the crossover tubes, pull the crossover tubes through the gas tank to install the fuel pump module.







2. CAUTION: Inspect the surfaces of the fuel pump module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new fuel pump module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE:
- Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.
- Apply clean engine oil to the O-ring seal.

Using the special tool, install the fuel pump module and lock ring.
- Install a new fuel pump module lock ring and O-ring seal.
- To install, tighten the fuel pump module lock ring until the lock tabs are seated against the stops.

3. NOTE: Make sure that the fuel crossover tubes are routed correctly.

Partially raise the fuel transfer pump and connect the internal fuel crossover hose quick connect couplings.







4. CAUTION: Inspect the surfaces of the fuel transfer pump flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new fuel transfer pump or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

NOTE:
- Make sure the alignment arrows on the fuel transfer pump and the fuel tank meet before tightening the fuel pump module lock ring.
- Apply clean engine oil to the O-ring seal.

Using the special tool, install the fuel transfer pump and lock ring.
- Install a new fuel transfer pump lock ring and O-ring seal.
- To install, tighten the fuel transfer pump lock ring until the lock tabs are seated against the stops.







5. Connect the electrical connector on the fuel transfer pump.







6. Connect the electrical connector on the fuel pump module.







7. Connect the fuel tube quick connect coupling on the fuel pump module.







8. Install the fuel pump module and fuel transfer pump access covers.
9. Install the rear seat bottom and any insulation padding covering the access covers.
10. Tighten the 2 fuel tank support strap bolts.
- Tighten to 35 Nm (26 lb-ft).

11. Connect the battery ground cable.