Fuel Pump Module
Fuel Pump Module
Removal and Installation
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in serious personal injury.
All vehicles
1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Carefully turn the fuel tank filler cap counterclockwise approximately one-fourth turn until the thread disengages and position aside.
4. NOTICE: When removing the Fuel Draining Hose, the fitting on the end of the hose can become detained by the safety valve. Carefully remove the hose using a gentle agitating motion to avoid detaching the hose from the fitting.
NOTE: The Fuel Draining Hose must be inserted into the fuel tank filler pipe until the fitting on the end of the hose enters into the fuel tank, opening the safety valve.
Insert the Fuel Draining Hose into the fuel tank filler pipe.
5. NOTE: This step will remove approximately one-eighth tank of fuel from a completely full fuel tank and the majority of any residual fuel from the fuel tank filler pipe. Also the fuel in the fuel tank will be below the Fuel Pump (FP) module mounting flange for FP module removal without fuel spillage.
Attach the Fuel Storage Tanker to the Fuel Draining Hose and remove approximately one-eighth tank of fuel (from a completely full tank), lowering the fuel level below the FP module mounting flange.
6. Remove the rear seat lower cushion.
Front Wheel Drive (FWD) vehicles
7. Remove the 4 screws and the FP module access cover.
- To install, tighten to 2 Nm (18 lb-in).
All-Wheel Drive (AWD) vehicles
8. Remove the 3 screws and the FP module access cover.
- To install, tighten to 2 Nm (18 lb-in).
All vehicles
9. Disconnect the FP module electrical connector.
10. Disconnect the fuel tube-to-FP module quick connect coupling.
11. NOTE: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the FP module from the vehicle to avoid fuel spillage inside the vehicle.
NOTE: Make sure to install a new FP module O-ring seal and lock ring.
Install the Fuel Tank Sender Unit Wrench. Remove and discard the FP module lock ring.
All-Wheel Drive (AWD) vehicles
12. Carefully lift the FP module out of the fuel tank enough to access and release the internal fuel tube-to-FP module quick connect coupling.
All vehicles
13. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.
NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.
Completely remove the FP module from the fuel tank.
14. NOTICE: Inspect the mating surfaces of the FP module flange and the 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 FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
NOTE: To install, apply clean engine oil to the new O-ring seal.
Remove and discard the FP module O-ring seal.
15. To install, reverse the removal procedure.
- Make sure the alignment tab on the FP module and the fuel tank meet before tightening the FP module lock ring.