REMOVAL & INSTALLATION
See Figures 1, 2 and 3
An electric fuel pump is used with fuel injection systems in order to provide higher and more uniform fuel pressures. It is located in the tank. To perform the testing or servicing, you will need a DRB III or equivalent scan tool.
- Release the fuel system pressure.
- Disconnect the negative battery cable.
- Open the trunk lid, then remove the trunk liner.
- Remove the access panel fasteners.
- Remove the access panel and gasket. Inspect the gasket for damage. If necessary, replace the gasket.
- Disconnect the electrical wiring from the top of the pump module.
- Disconnect the fuel supply and return tubes from the fuel pump module.
- Disconnect the hose from the pressure relief/rollover valve.
- A band clamp fastens the pump module to the tank. The module rises up from the tank after loosening the clamp.
- Loosen the band clamp until the pump module rises up from the tank.
- To absorb any possible spillage, place a shop towel around the access opening. Without removing the modular, tip it backwards to allow fuel in the reservoir to run down the side and back into the tank.
- The float arm of the sensor catches on the inside of the tank while removing the module. Tilt the module to the one side when removing it from the tank.
- Remove the pump module and gasket from the tank.
- Drain the remainder of fuel from the reservoir before servicing the pump module.
The fuel pump module and tank have alignment marks. The tank has two molded lines at the ten o'clock position. The fuel pump has a triangular alignment mark. Align the marks to correctly position the pump.
- With a new gasket, insert the pump straight into the tank to set the float on the bottom. Align the marks on the pump and tank.
- Seat the pump to tank by pushing the top downward. Make sure the gasket does not slip over the outside or inside edge of the tank lip. While holding the pump in the seated position, place the band clamp over the lip of the tank and edge of the pump. Tighten the band clamp to 31 inch lbs. (4 Nm). Do not over tighten.
- Install the fuel tubes over the return and supply nipples on the module.
- Connect the vent line to the pressure relief/rollover valve.
- Attach the electrical wiring to the pump.
- Using a DRB III or equivalent scan tool, pressurize the fuel system.
- Check for leaks.
- Install the access cover and gasket. Tighten the fasteners.
- Install the trunk liner.
- Connect the negative battery cable.
See Figures 4, 5, 6 and 7
- Release the fuel system pressure as described in earlier in this section.
- Remove the protective cover from the service valve on the fuel rail.
- Connect fuel pressure gauge C-4799B or equivalent to the fuel rail service valve.
- Place the ignition key in the ON position. Using the DRB III tester or equivalent, access the ASD fuel system test. (The ASD fuel system test will activate the fuel pump and pressurize the system.)
- If the gauge reading equals the specifications, then further testing is not required. Without vacuum applied to the regulator, the 3.3L engine fuel system operates at 55 psi (379 kPa). With the engine idling and the manifold vacuum applied to the regulator, the system operates at approximately 46 psi (317 kPa). Without vacuum applied to the regulator, the 3.5L engine fuel system operates at 48 psi (331 kPa). With the engine idling and the manifold vacuum applied to the regulator, the system operates at approximately 39 psi (269 kPa). The fuel system pressure varies with the different amounts of manifold vacuum applied to the regulator. If the pressure is not correct, record the pressure and remove the gauge.
- Ensure that the fuel does not leak from the fuel rail service valve. Install the protective cover onto the fuel rail service valve.
If the fuel pressure reading was below the specifications, test the system according to the following procedure:
- Perform the fuel pressure release procedure.
- Install a fuel gauge C4799 and fuel adapter 6631 or equivalent in the fuel supply line between the tank and the fuel filter.
- Using the DRB III scan tool or equivalent, with the ignition key in the ON position, repeat the ASD fuel system test.
- If the pressure is at least 5 psi (1 kPa) or higher than the reading recorded, replace the fuel filter.
- If no change is observed, gently squeeze the return hose. If the pressure increases, replace the pressure regulator. If the gauge reading does not change when the return hose is squeezed, the problem is either a plugged inlet strainer or defective fuel pump.
If the fuel pressure reading was above the specifications test the system according to the following procedure:
- Perform the pressure release procedure.
- Install fuel pressure gauge C4799 and adapter 6631 or equivalent in the fuel supply line between the fuel tank and the fuel filter.
- Remove the fuel return line hose from the pump at the tank. Connect pressure test adapter 6668 or equivalent to the return line. Place the other end of adapter 6668 into an approved gasoline container. A minimum of 2 gallon tank should be sufficient. All return fuel will flow into the container.
- Using the DRB III scan tool or its equivalent, with the ignition key in the ON position, repeat the ASD fuel system test.
- If the pressure is now correct, replace the fuel pump.
- If the pressure is still above specifications, remove the fuel return hose from the chassis fuel tubes (at the engine) and attach fuel pressure test adapter 6668 or equivalent to the return tube. Place the other end of the hose in the clean container, repeat the test. If the pressure is now correct, check for a restricted fuel return line. If there is no change observed, replace the fuel pressure regulator.