Fuel Tank Unit: Service and Repair
Fig. 9 Fuel Pump Module:
FUEL PUMP MODULE
The fuel pump module is installed in the top of the fuel tank Fig. 9. The fuel pump module contains the following:
- Electric fuel pump.
- Fuel pump reservoir
- Inlet strainer.
- Fuel pressure regulator.
- Fuel gauge sending unit
- Fuel supply and return line connections
The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.
Fig. 10 Fuel Pump Module Locknut:
ELECTRICAL PUMP REPLACEMENT
The electric fuel pump is not serviceable. If the fuel pump needs replacement, the complete fuel pump module must be replaced. Perform the Fuel System Pressure Release procedure before servicing the fuel pump. Service and Repair
WARNING: Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle.
FUEL PUMP MODULE REMOVAL
1. Remove fuel filler cap and perform Fuel System Pressure Release procedure. Service and Repair
2. Disconnect negative cable from auxiliary jumper terminal.
3. Remove fuel tank.
4. Disconnect fuel filter lines from fuel pump module.
5. Clean top of tank to remove loose dirt and debris.
6. Using Special Tool #6856 Fuel Pump Module Ring Spanner, remove locknut to release pump module Fig. 10.
WARNING: The fuel reservoir or the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.
Fig. 11 Fuel Pump Module Removal:
7. Remove fuel pump module and 0-ring from tank Fig. 11. Discard 0-ring.
FUEL PUMP MODULE INSTALLATION
1. Wipe seal area of tank clean. Place a new 0-ring on the ledge between the tank threads and the pump module opening.
2. Position fuel pump module in tank.
- Make sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.
CAUTION: Over tightening the pump lock ring may result in a leak.
3. While holding the pump module in position, install locknut. Tighten locknut to 61 Nm (45 ft lb) torque using special tool #6856.
4. Install fuel tank and fuel filter.
5. Fill fuel tank with clean fuel. Check for leaks.
6. Install negative cable to auxiliary jumper terminal.
Fig. 12 Inlet Strainer Removal:
FUEL PUMP INLET STRAINER SERVICE - REMOVAL
1. Remove fuel pump module.
2. Using a thin straight blade screwdriver, carefully pry back the locking tabs on fuel pump reservoir and remove the strainer Fig. 12.
3. Remove strainer 0-ring from the fuel pump reservoir body.
4. Remove any contaminants by washing the inside of the fuel tank.
INSTALLATION
1. Lubricate the strainer 0-ring with clean motor oil.
2. Insert strainer 0-ring into outlet of strainer so that it sits evenly on the step inside the outlet.
3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer.
4. Install fuel pump module.
Fig. 14 Fuel Pump/Level Sensor Electrical Connector:
FUEL LEVEL SENSOR
The fuel level sensor attaches to the side of the fuel pump module. Remove the fuel pump module to replace the fuel level sensor.
Fig. 14 Fuel Pump/Level Sensor Electrical Connector:
NOTE: Remove fuel pump module to gain access to this sensor.
REMOVAL
1. Depress retaining tab and remove fuel pump/level sensor connector from bottom of fuel pump module electrical connector Fig. 14.
Fig. 15 Terminal Removal Tool:
2. Using Special Tool #C-4334 terminal remover or equivalent, remove terminals from level sensor connector Fig. 15.
Fig. 16 Loosening Level Sensor:
3. Insert a screwdriver between the fuel pump module and the top of the level sensor housing Fig. 16. Push level sensor down slightly.
4. Slide level sensor wires through opening fuel pump module.
5. Slide level sensor out of installation channel in module.
Fig. 17 Groove In Back Side Of Level Sensor:
INSTALLATION
1. Insert level sensor wires into bottom of opening in module.
2. Wrap wires into groove in back of level sensor Fig. 17.
Fig. 18 Installation Channel:
3. While feeding wires into guide grooves, slide level sensor up into channel until it snaps into place Fig. 18. Ensure tab at bottom of sensor locks in place.
Fig. 19 Fuel Pump/Level Sensor Electrical Connector:
4. Install level sensor wires in connector.
- Push the wires up through the connector and then pull them down until they lock in place.
- Ensure signal and ground wires are installed in the correct position Fig. 19.
5. Install locking wedge on connector.
6. Push connector up into bottom of fuel pump module electrical connector.
7. Install fuel pump module.
Fig. 20 Fuel Pressure Regulator:
FUEL PRESSURE REGULATOR
The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 338 kPa (49 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port.
System fuel pressure reflects the amount of fuel pressure required to open the return port.
The fuel pressure regulator is part of the fuel pump module Fig. 20. Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator.
NOTE: Remove the fuel pump module from the fuel tank for access to the fuel pressure regulator.
REMOVAL
1. Spread tangs on pressure regulator retainer Fig. 20.
Fig. 21 Fuel Pressure Regulator Removal:
2. Pry fuel pressure regulator out of housing Fig. 21.
3. Ensure both upper and lower 0-rings are removed from regulator housing and discarded.
Fig. 22 Fuel Pressure Regulator O-Rings:
INSTALLATION
1. Lightly lubricate the 0-rings with engine oil and place them into opening in regulator housing Fig. 22.
2. Push regulator into opening in pump module.
3. Fold tangs on regulator retainer over tabs on housing.