Fuel Pump Module - Installation

ALL WHEEL DRIVE

Special Tools:






MAIN FUEL PUMP MODULE





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.

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





2. Connect the internal fuel line to the main fuel pump module.





3. Lower the main fuel pump module into the fuel tank using caution not to bend the float arm.






NOTE: The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.

4. Align the rubber O-ring seal and rotate the main fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.





5. Position the lock-ring over top of the main fuel pump module.
6. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
7. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.





9. Connect the fuel line (3) to the main fuel pump module.
10. Connect the electrical connector (2) to the main fuel pump module (1).





11. Install the main fuel pump module access cover.
12. Install the rear seat.
13. Install the negative battery cable.
14. Use the Scan Tool to pressurize the system and check for leaks.

AUXILIARY FUEL PUMP MODULE





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.

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





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






NOTE: The auxiliary fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.

4. Align the rubber O-ring seal and rotate the auxiliary fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.





5. Position the lock-ring over top of the auxiliary fuel pump module.
6. Position the Fuel Tank Module Wrench into the notches on the outside edge of the lock-ring.
7. Install a 1/2 inch drive breaker bar into the Fuel Tank Module Wrench.
8. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.





9. Connect the auxiliary fuel pump module electrical connector (2).





10. Install the auxiliary fuel pump module access cover.
11. Install the rear seat.
12. Install the negative battery cable.
13. Use the Scan Tool to pressurize the system and check for leaks.