Fuel Tank Pump Module Replacement

REMOVAL PROCEDURE

Tools Required
^ J 34730-1A Fuel Pressure Gauge
^ J 39765 Fuel Sender Lock Nut Wrench
^ J 42960-1 Fuel Tank Drain Hose
^ J 42960-2 Fuel Flapper Door Holder

CAUTION: Refer to the Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure. Service and Repair
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank.
5. Remove the fuel sender assembly.
6. Note the position of the fuel strainer (4) on the fuel pump.
7. Support the fuel sender assembly with one hand and grasp the strainer (4) with the other hand.
8. Pull the strainer off the pump. Discard the strainer after inspection.
9. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
10. Remove the fuel pressure regulator retaining clip (2).
11. Remove the fuel pressure regulator (3) from the housing on the fuel return pipe.
12. Disconnect the fuel pump electrical connector (7).
13. Remove the fuel level sensor electrical connector retaining clip (9).
14. Disconnect the fuel level sensor electrical connector (8) from under the fuel sender cover.
15. Remove the fuel level sensor retaining clip (6).
16. Squeeze the locking tangs and remove the fuel level sensor (5).
17. Remove the fuel pressure sensor (1).

INSTALLATION PROCEDURE
1. Install the fuel pressure sensor (1).
2. Install the fuel level sensor (5).
3. Install the fuel level sensor retaining clip (6).
4. Connect the fuel level sensor electrical connector (8).
5. Connect the fuel level sensor electrical connector retaining clip (9).
6. Connect the fuel pump electrical connector (7).
7. If needed, clean the fuel pressure regulator filter screen with gasoline.
8. Lubricate the fuel pressure regulator large and small O-rings with clean engine oil.
9. Install the fuel pressure regulator (3) into the housing on the fuel return pipe.
10. Install the fuel pressure regulator retaining clip (2).

IMPORTANT: Always install a new fuel strainer when replacing the fuel tank fuel pump module.

11. Install a new fuel strainer (4) in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
12. Install the fuel sender assembly.
13. Perform the fuel tank leak check. Refer to Fuel Tank Leak Check.
14. Install the fuel tank.
15. Refill the fuel tank.
16. Install the fuel filler cap.
17. Connect the negative battery cable.
18. Inspect for leaks.
18.1. Turn the ignition switch ON for 2 seconds.
18.2. Turn the ignition switch OFF for 10 seconds.
18.3. Turn the ignition switch ON.
18.4. Check for fuel leaks.
19. Perform the idle learn procedure. Refer to PCM Idle Learn Procedure. PCM Idle Learn Procedure