Removal and Replacement

FUEL PUMP MODULE REPLACEMENT [2.0L ENGINE NON-TURBO, 2.4L ENGINE (FWD)]

1. Remove the rear seat cushion assembly Rear Seat Assembly Removal and Installation).





2. Remove the floor inspection lid (LH).





3. Disconnect the fuel pump module connector and fuel tank differential pressure sensor connector.
4. Release the fuel pressure in the fuel line Service and Repair) [2.0L ENGINE Non-turbo] or Service and Repair) [2.4L ENGINE].





5. Insert a flat-tip screwdriver [6mm (0.24 inch) wide and 1mm (0.04 inch) thick] into the retainer of the fuel main pipe connector.





6.
CAUTION:
When pushing up the retainer of the fuel main pipe connector, pay attention to avoid damage to the retainer.

Turn the flat-tipped screwdriver inserted into the retainer by 90 degree angle to push up the retainer and unlock the fuel main pipe.
7. Disconnect the fuel main pipe from the fuel pump module.





8. Remove the fuel pump module mounting nuts.
9.
CAUTION:
Pay attention not to damage the fuel level sensor and float of the fuel pump module when removing it from the fuel tank through the service hole.

Remove the fuel pump module from service hole.
10. Replace the fuel pump module gasket with a new one.
11.
CAUTION:

- Pay attention not to damage the fuel level sensor and the float of the fuel pump module when installing it to the fuel tank through the service hole.

- When installing the fuel pump module to the fuel tank, check that the float of the fuel pump module moving area moves smoothly.

Install the fuel pump module to the fuel tank through the service hole, and tighten the fuel pump module mounting nuts to the specified torque.
Tightening torque: 2.5 ± 0.4 Nm (22 ± 4 in-lb)






12. Before the installation, push up the retainer of the fuel main pipe connector.





13. Connect the connector of fuel main pipe to the fuel pump module securely.
14.
CAUTION:

- When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.

- After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04inch) play.

Push in the retainer of the fuel main pipe connector to lock the fuel main pipe and fuel pump module.
15. Connect the fuel pump module connector and fuel tank differential pressure sensor connector.
16. Install the floor inspection lid (LH).
17. Install the rear seat cushion assembly Rear Seat Assembly Removal and Installation).