Fuel Pump: Service and Repair
FUEL PUMP MODULESpecial Tool(s):
Special Tool(s)
Removal and Installation
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. Failure to follow these instructions can result in 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 always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.
- This procedure involves fuel handling. Be prepared for spillage at all times and always observe fuel handling precautions. Failure to follow these instructions can result in personal injury.
All vehicles
1. With vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery ground cable.
4. Release the fuel tank filler cap and position aside.
5. Insert a suitable fuel drain tube into the fuel tank filler pipe until it reaches the fuel tank inlet spout.
6. NOTE: When the fuel tank is completely full, this step will remove approximately 1/8 of fuel from the fuel tank.
Attach the fuel storage tanker to the fuel drain tube and remove any residual fuel in the fuel tank filler pipe.
7. CAUTION: The fuel pump module, fuel level sensor and the fuel tank inlet spout are below the fuel level in the fuel tank when the fuel tank is completely filled. Make sure to drain any residual fuel from the fuel tank filler pipe prior to removing the fuel tank filler pipe clamp and hose.
Release the fuel tank filler pipe hose clamp.
- To install, tighten to 3 Nm (27 lb-in).
8. CAUTION: The fuel tank filler pipe may have some residual fuel remaining in it after draining. Upon disconnecting the fuel tank filler pipe hose, carefully drain the residual fuel into a suitable container.
Disconnect the fuel tank filler pipe hose from the fuel tank.
9. Insert a suitable fuel drain tube into the fuel tank inlet spout.
10. NOTE: When draining a completely full fuel tank, this step will drain most of the fuel from the RH side of the fuel tank, and partially drain the LH side of the fuel tank due to the siphoning effect from the fuel crossover tube.
Attach the fuel storage tanker to the fuel drain tube and drain the fuel from the RH side of the fuel tank.
Five Hundred, Montego
11. Remove the rear lower seat cushion.
- Release the latches and pull upward on the rear lower seat cushion and remove.
Freestyle
12. Position the second row seats to the forward folded position.
13. Release the 2 load floor support brackets and position the load floor upward.
14. Position the third row seats into the load floor.
15. Remove the 4 load floor support-to-floor pan retaining nuts.
- To install, tighten to 18 Nm (13 lb-ft).
16. Remove the 2 load floor support brackets.
All vehicles
17. Position the rear floor carpet and any padding or insulation covering the fuel pump module access cover aside.
18. Remove the fuel pump module access cover.
19. Clean the surrounding area of the fuel pump module mounting flange and the quick connect couplings with compressed air.
20. Disconnect the fuel pump module electrical connector.
21. NOTE: Place absorbant pads in the general work area in case of fuel spillage.
Disconnect the rear fuel supply tube-to-fuel pump module quick connect coupling.
22. Disconnect the fuel vapor control tube assembly valve-to-fuel pump module quick connect coupling.
23. Install the special tool and remove the fuel pump module lock ring.
24. Carefully lift the fuel pump module out of the fuel tank allowing access to disconnect the crossover tube quick connect couplings.
25. Disconnect the crossover tube-to-fuel pump module quick connect couplings.
26. CAUTION:
- The fuel pump module must be handled carefully to avoid damage to the float arm.
- Carefully remove the fuel pump module from the fuel tank to avoid fuel spillage inside the vehicle.
Completely remove the fuel pump module from the fuel tank.
27. 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.
- Make sure to install a new fuel pump module O-ring seal and lock ring.
NOTE: To install, apply clean engine oil to the O-ring seal.
Remove the fuel pump module O-ring seal.
28. To install, reverse the removal procedure.
- Make sure the alignment arrows on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.
- Tighten the fuel pump lock ring until it meets the stop tabs on the fuel tank.