Removal And Installation

REMOVAL 

1. Perform the fuel system pressure release. Refer to FUEL SYSTEM PRESSURE RELEASE  .
2. Disconnect and isolate the negative battery cable.
3. Remove the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .

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4. If equipped, lift up the underseat insulation to gain access to the fuel pump.
5. Lift the cover, undo the screws (1a) and move the fuel pump access cover (1b) to one side.

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6. Disconnect the fuel pump wire harness connector (1).
7. Disconnect the quick couplings for the fuel supply and return pipes (2) from the fuel pump.
8. Disconnect the quick coupling for the fuel breather and vapor recovery pipe (3).

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9. Mount the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (NAFTA) tool (1a) and remove the pump assembly mounting ring set (1b).

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10. Release the guide pins and Lift the pump drum flange (1).
11. Disconnect the quick coupling for the fuel breather and vapor recovery pipe (2).

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12. Disconnect the quick coupling (1) for the transfer chamber suction pipe
13. Disconnect the quick coupling (2) for the additional main chamber suction pipe.

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14. Disconnect the quick coupling (1) from the separator.

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15. Release the springs (1a) and remove the additional suction pipe (1b).

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16. Partially remove the fuel pump assembly (1).

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17. Disconnect the wire harness connector (1) for the transfer chamber level gauge.

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18. Remove the fuel pump assembly (1).

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19. Remove the O-ring (1) from the tank opening.

INSTALLATION 

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1. Be sure that the level sensor wiring is outside the tank (1).
2. Move the fuel lines inside the tank to the side and secure them into this position in a suitable manner.
3. Install the fuel pump module into the tank and push it towards the front wall of the tank.
   NOTE:

   Keep the upper portion of the fuel pump module on the outside of the fuel tank to aid in the installation of the fuel line connections

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4. Install the suction pipe into position and engine the retaining clips.
5. Connect the quick coupling to the separator.
   NOTE:

   Be sure that the coupling fully engaged.

6. Connect the quick coupling to the additional main chamber suction pipe.
   NOTE:

   Be sure that the coupling fully engaged.

7. Connect the quick coupling to the transfer chamber suction pipe.
   NOTE:

   Be sure that the coupling fully engaged.

8. 1. Make sure that the liquid/vapor separator pipe is between the drum and the metal rod of the fuel pump (1).

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9. Connect the wire harness connector for the transfer chamber level gauge.

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10. Install the pump drum flange back in place, partially engaging the guide pins (1a) and (1b) in the holes shown.
    NOTE:

    Do not use the hole (a) to locate the drum flange guide pins.

11. Check that the float switch rod is in the position shown (2).
12. Connect the quick coupling to the fuel breather and vapor recovery pipe to the connector on the upper portion of the fuel pump module.
    NOTE:

    Be sure that the coupling fully engaged.

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13. Install the upper portion of the fuel pump module guide pins into the fuel pump.
14. Install a new O-ring (1) onto the tank opening.

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15. Position the flange so that its appendix is positioned as shown.
16. Position the fuel pump assembly retaining nut onto the tank.
17. Mount the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench) (NAFTA) tool (2) and tighten the fuel pump assembly retaining nut.
18. Connect the quick coupling to the fuel breather and vapor recovery pipe.
    NOTE:

    Be sure that the coupling fully engaged.

19. Connect the fuel supply pipe quick coupling.
    NOTE:

    Be sure that the coupling fully engaged.

20. Connect the fuel pump module wire harness connector.
21. Install the fuel pump access cover in position and securely tighten the screws on the body.
22. Install the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
23. Connect the negative battery cable.
24. If the fuel pump module has been replaced, connect the scan tool to the vehicle, select the ECM, access the "Miscellaneous functions" menu and run the following procedures:
    • Fuel Supply Systems Components
    • Self-adapting parameter reset.
    NOTE:

    This procedure must be performed with the fuel system drained and tank empty. The two sections of the tank must be completely empty.