Fuel Pump: Service and Repair

NOTE: The electric fuel pump is not serviceable. If the fuel pump or electrical wiring harness needs replacement, the complete fuel pump module must be replaced.

REMOVAL
1. Release fuel system pressure.
2. Disconnect positive battery cable at the PDC.
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 fuel module cover.
6. Mark the fuel pump module location on the tank.
7. Use Special Tool # 6856 to remove fuel pump module locknut.
8. 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. Discard old seal.

INSTALLATION
1. Wipe seal area of tank clean and place a new seal in position in the tank opening.
2. Install new gasket on fuel tank.
3. Seat Fuel Pump Module in tank by pushing down on it, align the fuel pump module with the mark on the tank. Make sure that the level sensor float arm is forward in the tank.
4. Hand tighten the lock nut, then torque to 55 Nm (40 ft. lbs.) using Special tool # 6856.

CAUTION: Over tightening the pump lock ring may result in a leak.

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