Fuel Pump Control Unit: Service and Repair

Fuel Pump Module

Special Service Tools






Remover/Installer, Fuel Pump Module/Fuel Transfer Unit Locking Ring

310-146

Removal

WARNING: Place the vehicle in a quarantined area and arrange "No Smoking/Petrol Fumes" signs about the vehicle.

WARNING: Before any work is carried out on the fuel system, ground the vehicle to earth and maintain the ground connection until the work is complete.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

WARNING: The fuel system remains pressurized for a long time after the ignition is switched off. The fuel pressure must be relieved before attempting any repairs. Failure to follow these instructions may result in personal injury.

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. Failure to follow these instructions may result in personal injury.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.

WARNING: If taken internally, do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.

WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek immediate medical attention.

WARNING: Wash hands thoroughly after fuel handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention.
1 Raise and support the vehicle.
2
NOTE:
All vehicles.
Open the fuel tank filler pipe flap.
3 Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect
4 Detach the fuel tank filler pipe cap.
5 Release the pressure in the fuel system. For additional information, refer to Fuel System Pressure Release Service and Repair
6 Drain the fuel system. For additional information, refer to Fuel Tank Draining Procedures




7 Detach and reposition the door opening weatherstrip.




8 Remove the scuff plate trim panel.




9 Detach and reposition the floor covering.





10 Detach and reposition the rear seat cushion insulation.





11 Remove the floor aperture cover.





12 Disconnect the fuel pump module electrical connector.
- Detach the fuel pump module wiring harness from the retaining bracket.





13 Disconnect the fuel pump module quick release coupling.





14 Using the special tool, remove the fuel pump module locking ring.
- Remove and discard the O-ring seal.





15 Disconnect the fuel transfer module transfer feed tube.





16 Disconnect the left-hand fuel sender gauge electrical connector.





17 Disconnect the fuel transfer module transfer return tube.





18
CAUTION: Make sure no damage occurs to the fuel level float.
Remove the fuel pump module.
- Press down and rotate the base of the fuel pump module counter-clockwise.

Installation





1
CAUTION: On vehicles with supercharger make sure the arrow on the fuel pump module and the 'SC' marker on the fuel tank are aligned.
CAUTION: On vehicles without supercharger make sure the arrow on the fuel transfer module and the 'NA' marker on the fuel tank are aligned.
CAUTION: Make sure no damage occurs to the fuel level float.
NOTE:
All vehicles.
Install the fuel pump module.
- Press down and rotate the base of the fuel pump module clockwise.




2 Connect the transfer module transfer return tube.
- Make sure the coupling has latched onto the fuel pump module by pulling the tube after the connection has been made.




3 Connect the left-hand fuel sender gauge electrical connector.




4 Connect the fuel transfer module transfer feed tube.
- Make sure the quick release coupling has latched onto the fuel pump module fuel tube by pulling the tube after the connection has been made.




5 Using the special tool, install the fuel pump module locking ring.
- Install a new O-ring seal.
- Tighten to 60 Nm.




6 Connect the fuel pump module quick release coupling.
- Make sure the quick release coupling has latched onto the fuel pump module fuel pipe by pulling the pipe after the connection has been made.




7 Connect the fuel pump module electrical connector.
- Attach the fuel pump module wiring harness to the retaining bracket.




8 Install the floor aperture cover.




9 Attach the rear seat cushion insulation.





10 Attach the floor covering.





11 Install the scuff plate trim panel.





12 Attach the door opening weatherstrip.

13 Attach the fuel tank filler pipe cap.

14 Connect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect

15 Close the fuel tank filler pipe flap.