CTS 2006-2007, CTS-V 2005-2007, DTS 2006-2007

Fuel Pump

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Removal & Installation




CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:
    NOTE
    The fuel pump assembly may spring up from its position. The reservoir bucket on the assembly is full of fuel. Tip the assembly slightly so the float is not damaged during removal.



    Fuel tank
     
    Fuel tank pressure sensor
     
    Fuel tank connection cover electrical connector
     
    Spring loaded clamp around the tank boot
     
    Tank boot from the housing
     



    Fuel sender locking nut from the tank using a Fuel Tank Sender Wrench (J 45747)

    Click image to see an enlarged view

    Fig. Remove the locking nut using J-45747 fuel tank wrench

     
    Fuel pump electrical connectors
     
    Fuel tank connection cover
     
    Hose from the pump
     
    Fuel pump from the tank by pushing the tabs inward
     
    Locking ring by pushing the tabs in and pushing the locking ring from the housing simultaneously
     
    Fuel pump from the housing
     
    Lip seal from the cover by sliding it downward, past the reservoir and over the float arm and discard it
     

  8.  
  9. Drain the remaining fuel from the reservoir into an approved container.
  10.  

To install:

  1. Install or connect the following:

    New lip seal lubricated with engine oil
     
    Fuel pump into the housing
     
    Locking ring into the housing
     
    New fuel inlet screen
     
    Fuel pump assembly into the tank
     
    Fuel line to the pump using a new clamp
     
    Fuel pump electrical connectors
     
    Fuel tank connection cover
     
    Fuel sender locking nut. Torque the nut to 37 ft. lbs. (50 Nm).
     
    Fuel tank boot to the housing
     
    Fuel tank pressure sensor. Torque the fastener to 18 inch lbs. (4 Nm).
     
    Air reference hose to the pressure sensor
     
    Fuel feed and return lines using new clamps
     
    Fuel tank pressure sensor and connection cover electrical connectors
     
    Fuel tank to the vehicle. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank.
  4.  
  5. Start the vehicle and inspect for leaks.

    Click image to see an enlarged view

    Fig. Fuel pump module

  6.  


CAUTION
Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the rear compartment liner.

    Click image to see an enlarged view

    Fig. View of rear compartment removal

  6.  
  7. Remove the fuel sender access hole cover bolts.
  8.  
  9. Remove the fuel sender access hole cover.
  10.  
  11. Disconnect the fuel feed rear pipe quick connect fitting from the module.
  12.  
  13. Disconnect the fuel level sensor wiring harness electrical connectors from the pressure sensor and module.
  14.  
  15. Reposition the fuel feed pipe and harness connectors out of the way.
  16.  
  17. Install the J 45722 wrench to the lock ring.
    WARNING
    When removing the fuel module assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel module assembly O-ring seal and replace it with a new one.

  18.  
  19. Use the J 45722 and a long breaker-bar in order to unlock the fuel module lock ring. Rotate the lock ring in a counterclockwise direction.

    Click image to see an enlarged view

    Fig. J 45722 Fuel sender lock ring wrench

  20.  
  21. Remove the J 45722 and the fuel module lock ring.
  22.  
  23. Slowly raise the module until the fuel level sensor float arm is just visible.
  24.  
  25. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
  26.  
  27. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.
  28.  
  29. Remove and discard the fuel pump module O-ring seal.
  30.  
  31. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 different points.
  32.  
  33. If the warpage is less than 0.016 inch (0.41 mm) the lock ring does not require replacement.
  34.  
  35. If the warpage is greater than 0.016 inch (0.41 mm), the lock ring must be replaced.
    NOTE
    Some lock ring were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped.

  36.  

To install:

  1. Place a NEW fuel pump module O-ring seal onto the fuel tank.
  2.  
  3. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
  4.  
  5. Lower the module assembly into the tank.
  6.  
  7. Install the module lock ring, and move it into position on the top of the module.
  8.  
  9. Install the J 45722 to the lock ring.
    NOTE
    Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. Do not apply any type of lubrication in the seal groove.

  10.  
  11. Using the J 45722 and a breaker bar, rotate the fuel pump module lock ring clockwise until the ring is locked into place on the fuel tank.
  12.  
  13. Remove the J 45722.
  14.  
  15. Position the fuel feed pipe and harness connectors.
  16.  
  17. Connect the fuel level sensor wiring harness electrical connectors to the pressure sensor and module.
  18.  
  19. Connect the fuel feed rear pipe quick connect fitting to the module.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Perform the following procedure in order to inspect for leaks:

    Turn ON the ignition, with the engine OFF for 2 seconds.
     
    Turn OFF the ignition for 10 seconds.
     
    Turn ON the ignition, with the engine OFF .
     
    Inspect for fuel leaks.
     

  24.  
  25. Install the fuel sender access hole cover.
  26.  
  27. Install the fuel sender access hole cover bolts and tighten to 18 inch lbs. (2 Nm).
  28.  
  29. Install the rear compartment liner.
  30.  
  31. Install the fuel injector sight shield.
  32.  

 
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