Fuel Pump: Service and Repair

REMOVAL

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.

1. Drain the fuel. Refer to Draining Fuel Tank in the Fuel Tank.

WARNING: THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED. THE FUEL IN THE RESERVOIR WILL SPILL OUT WHEN THE MODULE IS REMOVED.

2. Remove fuel tank, refer to Fuel Tank Removal/Installation.
3. Lower tank.

Fuel Pump Module Removal:

Fuel Tank Locknut:

4. Use Special Tool 6856 to remove fuel pump module locknut.
5. Remove fuel pump and O-ring seal from tank. Discard old seal.

INSTALLATION
1. Wipe seal area of tank clean and place a new seal in position in the tank opening.

Alignment Tab:

2. Position fuel pump in the tank. Make sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank.
3. Position the locknut over the fuel pump module.
4. Tighten the locknut using Special Tool 6856 to 55 Nm (40.5 ft. lbs).

CAUTION: Over-tightening the pump lock ring may result in a leak.

5. Install fuel tank. Refer to Fuel Tank Removal/Installation.
6. Lower vehicle.
7. Fill fuel tank. Check for leaks.