Fuel pump module — removal and installation
1. Relieve the system fuel pressure (see Fuel pressure relief procedure).
2. Disconnect the cable from the negative battery terminal (see Engine electrical systems).
3. Remove the fuel tank (see Fuel tank — removal and installation).
4. Clean the top of the fuel pump module.
5. Disconnect the quick-connect fittings from the fuel pump module (see illustration).
8.5 Disconnect the quick-connect fittings from the fuel pump module
6. Note the orientation of the pump mounting flange and mark the orientation of the fuel pump in relation to the fuel tank (see illustration) to ensure that the fuel pump is correctly realigned when you install it again. If you’re going to install a new pump, note the location of your alignment mark on the old pump and make a mark at the same spot on the new unit.
8.6 To ensure that the pipes for the EVAP vent line, fuel tank vent line and fuel supply line are oriented correctly when you install the fuel pump module, make alignment marks on the tank and the pump flange at this wider part of the flange
7. Using a pair of large water pump pliers, unscrew the fuel pump module lock ring by turning it counterclockwise (see illustration). If the lock ring is tight or pliers will not work, use a hammer and a brass punch to loosen it (don’t use a steel punch, which could produce sparks when struck by the hammer)
8.7 Use a large pair of water pump pliers to unscrew the fuel pump lock ring; if the lock ring is too tight to loosen this way, carefully tap it loose with a hammer and a brass punch
8. Remove the pump assembly (see illustration), taking care not to damage the fuel level sensor float arm and float.
8.8 Carefully remove the fuel pump/ fuel level sensor module from the fuel tank; once the module has cleared the mounting hole in the tank, angle it as shown to work the float arm through the mounting hole without damaging anything
9. Before installing the pump, inspect the 0-ring (see illustration) for cracks, tears and deterioration. If it isn’t in perfect condition, replace it.
8.9 Remove and inspect the 0-ring seal for the fuel pump mounting flange; if it’s cracked, torn or deteriorated, replace it
10. The float arm may need to be installed onto the new fuel pump module. Note the installed position of the float arm on the old module and snap the float arm onto the new module in the same position.
11. Insert the fuel pump/fuel level sensor module into the fuel tank, align the mark that you made on the fuel pump/fuel level sending unit flange with the mark you made on the tank and carefully seat the pump flange on the tank. Make sure that you don’t damage the float arm or the float during installation. If the float arm is bent, the fuel level that is indicated on the fuel level gauge on the instrument cluster will be incorrect.
12. Remaining installation is reverse of removal.