Removal and Installation

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 mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions can result in personal injury.

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

Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the fuel tank filler cap.
Insert a suitable fuel drain hose into the fuel tank filler pipe until it reaches the fuel tank inlet tube.

Fig 1: Inserting Suitable Fuel Drain Hose Into Fuel Tank Filler Pipe

CAUTION: The fuel pump (FP) module and fuel level sensor will be below the fuel level in the tank when the tank is full. Make sure to drain 1/8 of the fuel capacity through the filler pipe prior to removing the pumps or fuel spillage will occur.

NOTE: When draining a completely full fuel tank, this step will remove approximately 1/8 of fuel from the LH side of the fuel tank.
Attach the fuel storage tanker to the fuel drain hose and remove as much fuel as possible from the fuel tank filler pipe.
Remove the rear seat bottom and any insulation padding covering the FP module access cover. For additional information, refer to SEATING .
Remove the FP module access cover.

Fig 2: Locating Fuel Pump Access Covers
Disconnect the FP module electrical connector.

Fig 3: Locating FP Module Electrical Connector
Release the quick connect coupling on the fuel pump module. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 4: Locating Quick Connect Coupling On FP Module
Using the special tool, remove the FP module retaining lock ring.

Fig 5: Removing FP Module Retaining Lock Ring

CAUTION: The FP module must be handled carefully to avoid damage to the float arm, filter and the convolute hoses.
Carefully lift the FP module out of the fuel tank enough to access and release the fuel cross over tube quick connect coupling from the FP module. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .

Fig 6: Identifying Cross-Over Fuel Tube Quick Connect Coupling
Completely remove the FP module from the fuel tank.
CAUTION: Inspect the surfaces of the FP module mounting flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new FP module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

CAUTION: Make sure to install a new FP module O-ring seal and lock ring.

NOTE: To install, apply clean engine oil to the O-ring seal.
Remove the FP module O-ring seal.