Fuel Tank Unit: Service and Repair

NOTE: Fuel tank removal will be necessary for fuel pump module removal.

WARNING: The fuel system is under a constant pressure even with engine off: before servicing the fuel pump module, fuel system pressure must be released.

1. Drain fuel tank and remove tank. Refer to the Fuel Tank/Service and Repair. Service and Repair
2. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.
3. Disconnect fuel line at filter/regulator.

Fig. 22 Top View Fuel Tank and Pump Module:

Fig. 23 Locknut Removal:

4. The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 22). Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 23). The fuel pump module will spring up when locknut is removed.
5. Remove module from fuel tank.

INSTALLATION

CAUTION: Whenever the fuel pump module is serviced, the module gasket must be replaced.

1. Using a new gasket, position fuel pump module into opening in fuel tank.
2. Position locknut over top of fuel pump module.
3. Rotate module until molded arrow (Fig. 22) is pointed toward front of vehicle (12 o'clock position). This step must be done to prevent float/float rod assembly from contacting sides of fuel tank.
4. Install Special Tool 6856 to locknut.
5. Tighten locknut to 34 Nm (25 ft. lbs.) torque.
6. Rotate fuel filter/fuel pressure regulator until its fitting is pointed toward front of vehicle 12 o'clock position.
7. Connect fuel line at filter/regulator.
8. Install fuel tank.