Fuel Pump Module Replacement

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.

REMOVAL
1. Remove fuel filler cap and perform Fuel System Pressure Release procedure.
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.

Fuel Pump Module Locknut:

6. Using Special Tool # 6856 Fuel Pump Module Ring Spanner, remove locknut to release pump module.

WARNING: THE FUEL RESERVOIR OF 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.

Fuel Pump Module Removal:

7. Remove fuel pump module and O-ring from tank. Discard O-ring.

INSTALLATION
1. Wipe seal area of tank clean. Place a new O-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 74.5 Nm (55 ft. lbs) 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.