Removal And Installation: AWD

REMOVAL

WARNING:

The fuel system is under constant high pressure even with engine off. Until the fuel pressure has been properly relieved from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Wear protective clothing and eye protection. Make sure the area in which the vehicle is being serviced is in a well ventilated area and free of flames/sparks.

NOTE:

AWD models equipped with a saddle tank, have a transfer pump on the right side that is serviced as an assembly with the fuel tank.

Partially drain the fuel tank if the fuel level gauge indicates that the tank is full. Refer to DRAINING FUEL TANK .
Perform the Fuel System Pressure Release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .
Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
Reposition the floor carpet to expose the fuel pump module access cover. Refer to CARPET, REMOVAL AND INSTALLATION .
Remove the fasteners and the fuel pump module access cover.

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1 - Fasteners
Unlock and disconnect the fuel pump module wire harness connector.

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1 - Fuel Pump Module Wire Harness Connector

2 - Supply Lines
Disconnect the fuel tank vapor and supply lines from the fuel pump module. Refer to QUICK-CONNECT FITTINGS .
NOTE:
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around the fuel tank opening.

Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the lock-ring.

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1 - Drive Breaker Bar

2 - Fuel Pump Lock Ring Wrench

3 - Lock-Ring

4 - Fuel Pump Module

Using a 1/2 inch drive breaker bar, rotate the wrench counterclockwise and remove the lock-ring.
WARNING:
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

NOTE:
Do not spill fuel into the interior of the vehicle.
Lift the fuel pump module up enough to access the internal fuel and vapor line connections using caution not to spill fuel inside the vehicle or bend the float arm.

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1 - Fuel Tank Vapor Line

2 - Fuel Tank Vapor Line
Disconnect the fuel tank vapor lines from the fuel pump module. Refer to QUICK-CONNECT FITTINGS .
Remove the fuel pump module out of the fuel tank using caution not to spill fuel inside the vehicle or bend the float arm.
Remove and discard the O-ring seal.

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1 - O-Ring Seal

INSTALLATION

WARNING:

Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.

CAUTION:

Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.

Clean the O-ring seal area of the fuel tank and install a NEW O-ring seal.

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1 - O-Ring Seal
Connect the fuel tank vapor lines to the fuel pump module. Refer to QUICK-CONNECT FITTINGS .

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1 - Fuel Tank Vapor Line

2 - Fuel Tank Vapor Line
Lower the fuel pump module into the fuel tank using caution not to bend the float arm. Line up the fuel pump module mounting tab to the arrow on the fuel tank.

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1 - Mounting Tab

Position the lock-ring over top of the fuel pump module.

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1 - Drive Breaker Bar

2 - Fuel Pump Lock Ring Wrench

3 - Lock-Ring

4 - Fuel Pump Module

Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the lock-ring.
Using a 1/2 inch drive breaker bar, rotate the wrench clockwise to tighten the lock-ring.
Remove the wrench and verify that all seven notches of the lock-ring have fully engaged.

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1 - Notch

2 - Lock Ring
Connect the fuel tank supply and vapor lines to the fuel pump module. Refer to QUICK-CONNECT FITTINGS .

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1 - Fuel Pump Module Wire Harness Connector

2 - Supply Lines
Connect and lock the fuel pump module wire harness connector.
Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.
Use the Scan Tool to operate the fuel pump and check for leaks.
Install the fuel pump module access cover fasteners and tighten to the proper torque specifications. Refer to TORQUE SPECIFICATIONS .

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1 - Cover Fasteners
Install the floor carpet. Refer to CARPET, REMOVAL AND INSTALLATION .