Transfer Fuel Pump - G6-, REMOVING AND INSTALLING, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES THROUGH 05/2010: Removing

WARNING: This page is about a different variant/trim than selected.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

The fuel tank must be completely empty to remove the fuel delivery unit. Procedure to empty the fuel tank FUEL TANK, DRAINING .

-- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

Fig 1: Cut The Floor Covering Along The Perforation

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WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the left side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove the nuts -1 to 4- and remove left locking flange cover.

-- Disconnect the connector -arrow- on the left locking flange.

Fig 3: Connecting Connector -Arrow- At Left Locking Flange

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-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 4: Identifying Removal Of Locking Ring With T10202

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-- Pull left locking flange with seal out of fuel tank a bit.

Fig 5: Locking Flange Connectors

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-- Disconnect the connectors -1 and 2- on the bottom of the left locking flange.

-- Reach into the fuel tank opening and disconnt the fuel lines -3 and 4-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 6: Fuel Lines Location

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NOTE:

Ignore items -1 and 2-.

-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

Fig 7: Cut The Floor Covering Along The Perforation

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WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 8: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove nuts -1 to 4- and remove right locking flange cover.

-- Disconnect the connector -3- on the right locking flange.

Fig 9: Identifying Fuel Return Line -1-, Fuel Supply Line -2- To Right Locking Flange, And Connector -3-

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NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Vehicles with parking heater: Disconnect the fuel line to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 10: Identifying Removal Of Locking Ring With T10202

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-- Pull right locking flange with seal out of fuel tank a bit.

Fig 11: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

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-- Disconnect electrical connectors -1 and 2 - on underside of the right locking flange.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 12: Fuel Lines Location

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-- Reach into the opening in the fuel tank and disconnect the delivery line -4- by pressing the releases.

-- Disconnect the suction jet line -3- to the suction jet pump. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Pull the fuel lines out through the right opening in the fuel tank.

-- Reach into the opening in the fuel tank and turn the fuel delivery unit -1- counterclockwise 15° -arrow- to release (bayonet connection).

Fig 13: Identifying Fuel Delivery Unit -1-, Notch -3-, And Retaining Ring Tab -4-

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NOTE:

The fuel delivery unit is illustrated without the fuel tank.

The notch -3- on the fuel delivery unit then aligns with the retaining ring tab -4-.

-- Remove the fuel delivery unit.

NOTE:

Be sure there is still some fuel inside the fuel delivery unit.