Fuel Level Sensor: Service and Repair

Fuel Pump Module









Removal and Installation

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: 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 component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Always disconnect the battery ground cable at the battery when working on an evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Release the fuel system pressure. For additional information, refer to Fuel System - General Information Service and Repair.

2. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

3. NOTE: The supplemental refueling adapter is located in the luggage compartment.

Install the supplemental refueling adapter and a length of semi-rigid fuel drain tube into the Easy Fuel(TM) (capless) fuel tank filler pipe until the tube enters the fuel tank.





4. NOTE: This step is to remove approximately one-fourth tank of the fuel from a completely full fuel tank and the majority of any residual fuel in the fuel tank filler pipe, lowering the fuel level below the Fuel Pump (FP) module flange.

Attach the Fuel Storage Tanker to the fuel drain tube and remove one-fourth (approximately 4 gallons) of fuel from the tank.

5. Remove the rear seat lower cushion. For additional information, refer to Seating Seat Cushion - Rear.

6. Remove the 4 screws and the FP module access cover.
- To install, tighten to 2 Nm (18 lb-in).

7. Disconnect the FP module electrical connector.

8. Disconnect the fuel tube-to-FP module quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.

9. NOTE: Place absorbent pads on the floor pan in the immediate area in case of fuel spills. Carefully remove the FP module from the vehicle to avoid fuel spillage inside the vehicle.

NOTE: Make sure to install a new FP module O-ring seal.

Install the Fuel Tank Sender Unit Wrench and remove the FP module lock ring.





10. NOTICE: The Fuel Pump (FP) module must be handled carefully to avoid damage to the float arm.

NOTE: The FP module will have residual fuel remaining internally, drain into a suitable container.

Completely remove the FP module from the fuel tank.

11. NOTICE: Inspect the mating surfaces of the Fuel Pump (FP) 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 FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

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

Remove and discard the FP module O-ring seal.

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