Fuel Pump Replacement (RPO NU6)

Fuel Pump Replacement (RPO NU6)

Tools Required

J 39765 Fuel Sender Lock Nut Wrench

Removal Procedure

Caution: Refer to Gasoline/Gasoline Vapors Caution.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.




1. Remove the fuel tank.
2. Using the J 39765, unlock the fuel sender lock ring.
3. Slowly lift the fuel pump flange up until the quick connect fittings (1) and fuel level sensor electrical connector are just visible.
4. Disconnect the fuel level sensor electrical connector from the fuel pump flange.
5. Disconnect the fuel tank vent valve and the fuel filter quick connect fittings (1) from the fuel pump flange.




6. Remove the fuel pump flange lock ring (1) and fuel pump flange (2). If required, remove the lock ring from the flange.
7. Remove and discard the fuel pump flange seal (3).




8. Squeeze the fuel pump quick connect fitting retainer (3) together in order to remove the fitting from the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service.
9. Reposition the fuel pump line.
10. Rotate the fuel pump to the left until the tab (1) is aligned with the opening in the fuel pump module.




11. Remove the fuel pump from the fuel pump module.

Installation Procedure




1. Align the fuel pump tab with the opening in the fuel pump module. Guide the fuel pump filter into the fuel pump module.
2. Install the fuel pump to the fuel pump module.




3. Rotate the fuel pump to the right until the tab (1) is locked into the fuel pump module.
4. Position the fuel pump line.
5. Install the fuel pump quick connect fitting (3) to the fuel filter.




6. Position a NEW fuel pump flange seal (3) onto the fuel tank.
7. If required, install the lock ring onto the flange. Position the fuel pump flange (2) and lock ring (1) over the fuel tank opening.
8. Ensure that the fuel pump flange tab is aligned with the arrow on the fuel tank.




9. Connect the fuel tank vent valve and the fuel filter quick connect fittings (1) to the fuel pump flange.
10. Connect the fuel level sensor electrical connector to the fuel pump flange.
11. Slowly lower the fuel pump flange into the fuel tank.
12. Using the J 39765, lock the fuel sender lock ring.
13. Install the fuel tank.