Module, Fuel Pump: Installation: Auxiliary

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.

WARNING:

The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.

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CAUTION:

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

Clean the rubber O-ring seal area of the fuel tank module opening and install a new rubber O-ring seal.

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Reconnect the internal fuel line to the auxiliary fuel pump module.
Lower the auxiliary fuel pump module into the fuel tank using caution not to bend the float arm.

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NOTE:
The fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation noted or marked during removal. This step must be performed for the fuel level gauge to work properly.

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Position the lock ring (1) over the top of the fuel pump module flange.
Position the (special tool #10521, Wrench, Fuel Pump Lock Ring) into the notches on the outside edge of the lock ring.
Install a 1/2 inch drive breaker bar into the (special tool #10521, Wrench, Fuel Pump Lock Ring).
Rotate the breaker bar clockwise until all seven notches of the lock ring have engaged.
Remove the screws (2) that secure the fuel module cover (3) to the floor.

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Connect the fuel pump module wire harness connector (2, 6).

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NOTE:
Right side shown, left side similar.
Install the access cover (3) and securely tighten the screws (2).
Position back the carpet access cover (1).

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Install the rear seat. Refer to SEAT, REAR, INSTALLATION .
Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
Use the Scan Tool to pressurize the system and check for leaks.