Fuel Pump: Service and Repair

REMOVAL
Fuel tank removal will be necessary for fuel pump module removal.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING FUEL PUMP MODULE, FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. Perform Fuel System Pressure Release Procedure.
2. Drain fuel tank and remove tank. Refer to Fuel Tank Removal/Installation.
3. Thoroughly wash and clean area around pump module to prevent contaminants from entering tank.

Fig. 16 Fuel Tank And Components:

4. Disconnect fuel return and pressure lines from fuel pump module fittings (Fig. 16). Refer to Quick-Connect Fittings for procedures.

Fig. 18 Locknut Removal/Installation - Typical:

5. The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 16). Install Special Tool 6856 to fuel pump module locknut and remove locknut (Fig. 18). The fuel pump module will spring up slightly after locknut is removed.
6. Remove module from fuel tank.

INSTALLATION
Fuel tank removal will be necessary for fuel pump module removal.

CAUTION: Whenever fuel pump module is serviced, module gasket must be replaced.

1. Thoroughly clean locknut threads and mating fuel tank threads. Use a soap/water solution. Do not use carburetor cleaner to clean threads.
2. Using new gasket, position fuel pump module into opening in fuel tank.
3. Apply clean water to locknut threads.
4. Position locknut over top of fuel pump module.

Fig. 19 Fuel Pump Module Indexing Arrow:

5. Rotate module until indexing arrow at top of module (Fig. 19) is pointed toward rear of vehicle. Align arrow to tick mark on top of fuel tank. This step must be done to prevent float/float rod assembly from contacting sides of fuel tank.
6. Install Special Tool 6856 to locknut.
7. Tighten locknut to 74 Nm (55 ft. lbs.) torque.
8. Connect fuel return and pressure lines to fuel pump module fittings (Fig. 16). Refer to Quick-Connect Fittings.
9. Install fuel tank. Refer to Fuel Tank Installation.