Fuel Pump Module - Removal
REMOVAL
Special Tools:
MAIN FUEL PUMP MODULE
WARNING: The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks. Failure to comply may result in serious or fatal injury.
WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.
CAUTION: If the electric fuel pump module is not operating or the fuel level sending unit is not operating and the fuel level cannot be determined, the fuel tank must be removed prior to draining. If the fuel level is above 5/8 of a tank and the fuel pump module lock-ring is removed, fuel will spill into the interior of the vehicle
1. Verify the fuel level is below 5/8 of a tank.
2. Perform the fuel pressure release procedure Service and Repair.
3. If required, perform the draining fuel tank procedure . Procedures
4. Disconnect the negative battery cable.
5. Push the rear lower seat cushion up and back and remove the seat cushion.
6. Fold back the foam pad covering the fuel pump module plastic access covers.
7. Remove the left side main fuel pump module plastic access cover.
8. Disconnect the electrical connector from the main fuel pump module.
CAUTION: An indexing arrow is located on top of the fuel pump module to clock it's position into the fuel tank, note it's location for reassembly.
NOTE: Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
9. Mark the main fuel pump module orientation.
10. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the lock ring.
11. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
NOTE: The main fuel pump module will spring up slightly when the lock ring is removed.
12. Rotate the breaker bar counterclockwise and remove the lock ring.
CAUTION: Do not allow the float arm of the Main Fuel Pump Module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
13. Raise and separate the top section from the bottom section of the main fuel pump module.
14. Disconnect the electrical connectors from under the top section of the main fuel pump module.
15. Remove the top section of the main fuel pump module from the vehicle.
16. Press the quick connect release tab (3) and remove the fuel supply line (1) from the main fuel pump module.
17. Disconnect the fuel return lines (1,2) from the main fuel pump module.
NOTE: Do not spill fuel into the interior of the vehicle.
18. Carefully lift the bottom section of the main fuel pump module out of the fuel tank, tip the bottom section on its side and drain the remaining fuel from the bottom reservoir into the fuel tank and remove from vehicle.
NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be replaced.
19. Remove and discard the rubber O-ring seal.
AUXILIARY FUEL PUMP MODULE
NOTE: The Main Fuel Pump Module must be removed for Auxiliary Fuel Pump Module removal.
1. Remove the main fuel pump module, see MAIN FUEL PUMP MODULE.
2. Remove the auxiliary fuel pump module plastic access cover (1) from the floor pan.
NOTE: Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
3. Disconnect the fuel supply line (2) from the auxiliary fuel pump module (1).
4. Mark the auxiliary fuel pump module orientation.
5. Position the SAE Fuel Pump Lock Ring Wrench (1) into the notches on the outside edge of the lock ring (2).
6. Install a 1/2 inch drive breaker bar into the SAE Fuel Pump Lock Ring Wrench (1).
7. Rotate the breaker bar counterclockwise and remove the lock ring (2).
CAUTION: Do not allow the float arm of the Auxiliary Fuel Pump Module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
8. Lift the auxiliary fuel pump module up and out of fuel tank while guiding the fuel supply and return lines out from the left side of the fuel tank.
NOTE: Whenever a fuel pump module is serviced, the rubber O-ring seal must be replaced.
9. Remove and discard the rubber O-ring seal.