Main Fuel Pump Module

REMOVAL

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. 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.

WARNING:

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 main fuel pump module, use compressed air to remove any accumulated dirt and debris from around the fuel tank opening.

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1 - Main Fuel Pump Module Wire Harness Connector

2 - Fuel Supply Line Quick Connector Fitting

3 - Retaining Tabs

4 - Fuel Pressure Sensor

Disconnect the main fuel pump module wire harness connector.
Release the retaining tabs and disengage the fuel pressure sensor from the fuel tank.
Disconnect the fuel supply line quick connector fitting from the fuel pump module. Refer to QUICK CONNECT FITTINGS .

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1 - Main Fuel Pump Module Lock Ring

2 - Main Fuel Pump Module
Position the (special tool #9340, SAE Fuel Pump Lock Ring Wrench) into the notches on the outside edge of the main fuel pump module lock ring.
Install a 1/2 inch drive breaker bar onto the SAE Fuel Pump Lock Ring Wrench.
NOTE:
The main fuel pump module will spring up slightly when lock ring is removed.
Rotate the breaker bar counterclockwise and remove the main fuel pump module lock ring lock ring.

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1 - Main Fuel Pump Module

2 - Indexing Tab
Note the indexing tab location on the main fuel pump module for reassembly.

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1 - Auxiliary Fuel Pump Module Supply Line Connection

CAUTION:
Do not allow the float arm of the main 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 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.
Tip the main fuel pump module on its side to drain the remaining fuel from the reservoir and remove the main fuel pump module.
CAUTION:
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
Remove and DISCARD the rubber O-ring seal.

INSTALLATION

CAUTION:

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

Position a NEW rubber O-ring seal onto the fuel tank flange.
CAUTION:
Do not allow the float arm of the main 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 main fuel pump module into the fuel tank enough to gain access to the auxiliary fuel pump module supply line connector and connect the supply line.
Rotate the main 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 main 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 supply line quick connector fitting to the fuel pump module. Refer to QUICK CONNECT FITTINGS .
Engage the fuel pressure sensor to the fuel tank.
Connect the main fuel pump module wire harness connector.
Install the fuel tank. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
Start the engine and check for leaks at all fuel system connections.