Auxiliary Fuel Pump Module
REMOVAL
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. 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. Failure to comply may result in serious or fatal injury.
No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked OSHA approved containers. Wear protective clothing. Risk of injury to eyes and skin from contact with fuel.
- Perform the fuel system pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE .
- Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
- Remove the fuel tank. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
- Prior to removing the auxiliary fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
1 - Auxiliary Fuel Pump Module Supply Line Connection - Partially remove the main fuel pump module out of the fuel tank enough to gain access to the auxiliary fuel pump module supply line connection and disconnect the supply line. Refer to MODULE, FUEL PUMP, REMOVAL AND INSTALLATION
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1 - Auxiliary Fuel Pump Module Wire Harness Connector 2 - Fuel Vapor Recirculation Line Quick Connect Fitting 3 - Fuel Vapor Tube Quick-Connect Fitting - Disconnect the auxiliary fuel pump module wire harness connector.
- Disconnect the fuel vapor recirculation line quick connect fitting. Refer to QUICK CONNECT FITTINGS .
- Disconnect the fuel vapor tube quick connect fitting. Refer to QUICK CONNECT FITTINGS
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1 - Auxiliary Fuel Pump Module Lock Ring 2 - Auxiliary Fuel Pump Module - Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the auxiliary fuel pump module lock ring.
- Install a 1/2 inch drive breaker bar onto the SAE Fuel Pump Lock Ring Wrench.
- Rotate the breaker bar counterclockwise and remove the auxiliary fuel pump module lock ring.
1 - Auxiliary Fuel Pump Module 2 - Indexing Tab - Note the indexing tab location on the auxiliary fuel pump module for reassembly.CAUTION:
Do not allow the float arm of the auxiliary fuel pump module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
- Using caution not to bend the float arm, lift the auxiliary fuel pump module and the auxiliary fuel pump module supply line out of the fuel tank.CAUTION:
Whenever the auxiliary fuel pump module is serviced, the rubber O-ring seal must be replaced.
- Remove and DISCARD the rubber O-ring.
INSTALLATION
Whenever the auxiliary fuel pump module is serviced, the rubber O-ring seal must be replaced.
- Install a NEW
rubber O-ring onto the fuel tank flange.CAUTION:
Do not allow the float arm of the auxiliary fuel pump module to come in contact with any part of the fuel tank during removal or installation, damage to the float arm and fuel level sending card may result.
- Using caution not to bend the float arm, lower the auxiliary fuel pump module and the auxiliary fuel pump module supply line into the fuel tank as an assembly.NOTE:
The auxiliary fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
- Rotate the auxiliary fuel pump module until the indexing tab aligns to the same position as noted during removal. This step must be performed to prevent the float from contacting the side of the fuel tank.
- Position the lock ring over top of the auxiliary fuel pump module.
- Install the SAE Fuel Pump Lock Ring Wrench into the notches on the outside edge of lock ring.
- Install a 1/2 inch drive breaker bar onto the SAE Fuel Pump Lock Ring Wrench.
- Rotate the breaker bar clockwise until all seven notches have engaged.
- Connect the fuel vapor tube quick connect fitting. Refer to QUICK CONNECT FITTINGS .
- Connect the fuel vapor recirculation line quick connect fitting. Refer to QUICK CONNECT FITTINGS .
- Connect the auxiliary fuel pump module wire harness connector.
- Using caution not to bend the float arm, connect the auxiliary fuel pump module supply line connector to the main fuel pump module. Install the main fuel pump module. Refer to MODULE, FUEL PUMP, REMOVAL AND INSTALLATION .
- Install the fuel tank. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
- Start the engine and check for leaks at all fuel system connections.