Fuel Pump: Service and Repair

REMOVAL
1. Release fuel system pressure.
2. Disconnect negative battery cable at the auxiliary terminal.
3. Access fuel pump module cover by pulling trunk rug back.
4. Drill pop rivets from fuel pump module cover using a 1/4 drill.
5. Remove cover.
6. Use Special Tool 6856 to remove fuel pump module locknut.
7. Lift module up to remove being careful not to spill the residual fuel that is left in it.
- The float arm of the level sensor catches on the inside of the fuel tank while removing the module.
- Tilt the module assembly to one side while removing it.

INSTALLATION
1. Install new gasket on fuel tank.
2. Seat Fuel Pump Module in tank by pushing down on it, align the regulator to the rear and the rollover valve forward.
3. Hand tighten the lock nut, then torque to 25 Nm (34 ft. lbs.) using Special tool 6856.
4. Connect negative battery cable at the auxiliary terminal.

CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Off position.

5. Use the DRB Scan Tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
6. Install fuel pump module cover using pop rivets.
7. Install rug in trunk.