Fuel Pump: Service and Repair

FUEL PUMP AND GAUGE SENDER UNIT - ADVANCED EVAPS

A plastic fuel tank with a combined fuel pump and gauge sender unit is fitted. The top flange of the pump also houses a pressure sensor which is not removable from the pump. The fuel pump is accessed through a panel in the load space floor.

WARNING : Ensure that fuel handling precautions are strictly adhered to when carrying out following instructions.

CAUTION: Before disconnecting any part of fuel system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into fuel system.

Remove
1. Depressurize fuel system. See Fuel Pressure Regulator.
2. Disconnect battery earth lead.
3. Check the amount of fuel in the tank. If the tank is full. drain 2.4 US gallons (9 liters) minimum.





4. Remove 6 screws securing tail door tread strip and remove tread strip.
5. Remove RH luggage compartment side panel.





6. Fold back loadspace carpet and sound insulation to reveal access panel.
7. Remove 6 screws securing fuel pump access panel.
8. Remove access panel.





9. Disconnect multiplugs from fuel pump and pressure sensor.
10. Release vent hose from pressure sensor body.
11. Noting their fitted positions, disconnect both fuel connections by pressing the black release latches on each connector and pushing the connector back down the line. Care must be taken to catch any excess fuel which may spill from the fuel lines once removed.





12. Using service tool LRT-19-009 loosen and remove the metal locking ring.
13. Pry the pump from the tank opening using a blunt instrument under the edge of the pump flange. Once clear of the seal, tip the pump to the right to allow fuel contained in the body of the pump to drain into the tank.

CAUTION: Do not lift the pump from the tank using the feed and return stubs.

14. Remove and discard seal.

Refit
15. Fit NEW pump seal to tank opening.
16. Carefully lower pump into tank opening, pressing firmly on the pump top flange to allow correct positioning.

NOTE: Ensure location tag on pump top flange is engaged correctly to tank opening lip.

17. Fit locking ring and tighten to 35 Nm using service tool LRT-1 9-009.
18. Connect both fuel lines to the pump by pushing the connectors down each line square to the pump connection until the connectors positively latch.
19. Connect vent hose to pressure sensor body.
20. Connect multiplugs to fuel pump and pressure sensor.
21. Connect battery earth lead.
22. Refill tank with drained fuel.
23. Run the engine to check for any fuel leaks.
24. Fit access panel and secure with screws.
25. Reposition loadspace sound insulation and carpet.
26. Fit RH luggage compartment side panel.
27. Fit tail door tread strip and secure with screws.