Fuel Pump: Service and Repair

Fuel delivery unit, removing and installing

WARNING: Fire hazard! Do NOT have anything in the area that can ignite gasoline!

Special tools and equipment





^ 3217 Ring nut wrench

Removing
- Note safety precautions before starting work, Refer to Vehicle Damage Warnings, Service Precaution, Vehicle Damage Warnings

CAUTION: Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap!

- With ignition switched OFF, disconnect battery Ground strap.
- Fold bench seat forward.
- Remove cover under bench seat.
- Remove metal cover for fuel delivery unit (three screws).

WARNING: Fuel supply lines are under pressure! Before removing from hose connection, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.





- Disconnect 4-pin harness connector and supply and return lines -arrows- from flange.

Note: Press down on fuel line connectors to release.





- Remove union nut using 3217 wrench.
- Pull fuel delivery unit and seal out of fuel tank opening.

Note: If the delivery unit being replaced; properly drain old delivery unit before disposal.

Installing
Installation is carried out in the reverse order of the removal procedure.

Note:
^ Do not bend the fuel sensor when installing.
^ Insert seal for fuel delivery unit dry into opening of fuel tank.
^ Moisten seal with fuel only when installing fuel delivery unit.
^ Ensure that fuel hoses are securely seated.





^ Note installed position of fuel delivery unit flange: Mark on flange must align with mark on fuel tank -arrows-.
^ After installing fuel delivery unit, check that the supply, return and vent lines are still clipped to the fuel tank.

- Check DTC memory:
Refer to Powertrain Management
- Match Engine Control Module to Throttle Control Module:
- Check Readiness code:
Refer to Powertrain Management
- If DTCs are stored in the ECM or ECM receives low voltage when ignition is on, Readiness code must be reset:
Refer to Powertrain Management