Fuel Level Sensor: Service and Repair

FUEL PUMP MODULE

Special Tool(s):

Special Tool(s)







Removal and Installation

WARNING:
- Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.
- Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard.

1. Release the fuel system pressure.
2. Disconnect the battery ground cable.
3. Remove the rear seat lower cushion.







4. Remove the 4 screws and the fuel pump module access cover.
5. Disconnect the fuel pump module electrical connector.
6. Disconnect the fuel supply tube-to-fuel pump module quick connect coupling.







7. Using the special tool, remove the fuel pump module lock ring retainer.







8. Position the fuel pump module aside and insert the tube from the fuel storage recovery tanker. Completely drain the fuel from the fuel tank.

9. CAUTION:
- The fuel pump module must be handled carefully to avoid damage to the float arm.
- Place absorbant pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the fuel pump module from the vehicle to avoid fuel spillage inside the vehicle.
- The fuel pump module will have residual fuel remaining internally, drain into a suitable container.

Completely remove the fuel pump module from the fuel tank.

10. CAUTION:
- Inspect the mating surfaces of the fuel pump module flange and the fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new fuel pump module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new fuel pump module O-ring seal and lock ring.

NOTE: To install, apply clean engine oil to the O-ring seal.

Remove the fuel pump module O-ring seal.

11. To install, reverse the removal procedure.
- Make sure the alignment tab on the fuel pump module and the fuel tank meet before tightening the fuel pump module lock ring.