Question about 1998 GMC Sierra

2 Answers

Removal of fuel lines from fuel pump assembly

I've gained access to the fuel pump assembly on top of the tank but the hoses are attached with some sort of factory fitting and I can't figure out how to disconnect them. Is there a way or do I need a special tool?

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  • Expert
  • 124 Answers

There is special disconnect tool just for 98-00 classic CK pickups. Lisle makes them they are a two piece plastic tool that is pretty cheap to buy. Do not buy a regular disconnect tool bcause they will not fit in the lines at the pump. The lisle number at Carquest is 37500. Please rate.

Posted on Dec 27, 2008

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  • GMC Master
  • 1,779 Answers

The lines can be disconnected w/out a special tool, but u can pick one up a set for different size lines at any auto parts store for a few bucks, and it'll make the job easy. W/out the tool, you'll probably damage the connection trying to separate it.

Posted on Dec 27, 2008

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1 Answer

Does the 2004 cadillac deville have a access panel or do I have to remove the tank to gain acess to fuel pump


lucky you, you can get to it from the trunk.

Removal & Installation

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the fuel system pressure.
  3. Drain the fuel tank.
  4. Remove or disconnect the following:
    CAUTION When removing the fuel sender from the tank, the reservoir bucket is full of fuel. Use caution in containing the fuel.

    NOTE Note the direction the strainer is pointing.


    Negative battery cable Spare tire and jack Trunk lining Fuel sender access panel Sender and quick connect fittings from the sender Electrical connector from the sender and position harness and hoses aside


    Sender retaining ring Sender and take note of its position Fuel sender O-ring and discard it


    Strainer from the pump by pulling it down and twisting Pump electrical wires and hoses Pump assembly out of the rubber connectors

To install:
  1. Transfer any insulators and grommets from the old pump to the new one.
  2. Connect the pump to the fuel hose and tilt the bottom of the pump into the mounting bracket.
  3. Install or connect the following:

    New strainer on the pump so it points in the same direction as noted during removal Electrical connectors and fuel lines to the pump New O-ring on top of the fuel tank Fuel sender assembly into the tank Lockring Fuel line quick connectors Sender electrical connector Fuel sender access cover Trunk liner Spare tire and jack
  4. Refill with fuel and check for leaks.

Sep 03, 2011 | 2004 Cadillac Deville

1 Answer

How to replace a fuel pump on a1997 Chev Venture



  1. Properly relieve the fuel system pressure and install a pressure test gauge according to the tool manufacturers instructions.
  2. Turn the ignition switch to the ON position for 3 seconds, then turn to the OFF position for 5 seconds. Repeat this procedure two or three times to pressurize the system. Again turn the switch to the ON position.
    1. On TBI equipped vehicles, the gauge should read a static pressure of between 9 and 13 psi (62-89kPa)
    2. On SFI equipped vehicles, the gauge should read a static pressure of between 41 and 47 psi (248-325kPa)
    3. If not, check for a clogged fuel filter, a kinked fuel line, or an inoperative fuel pump.
  3. On TBI equipped vehicles, the fuel pressure will drop after the fuel pump stops running due to a controlled bleed in the fuel system. Use of the fuel pressure gauge will determine if the fuel system pressure is enough for the engine to start and run.
  4. No fuel spray from the injector indicates a faulty fuel or ignition system or no PCM control of the injector.
  5. This test will determine if the ignition control module is not generating the reference pulse or if the wiring or PCM are at fault. By touching and removing a test light to B+ on CKT 430 (purple/white wire from the ignition system), a reference pulse should be generated. If the injector test light blinks, the PCM and wiring are OK.







If the pump tests bad...
Disconnect the negative battery cable.
  1. Relieve the fuel system pressure.
  2. Block the front wheels and raise and support the rear of the vehicle safely. Make sure the rear is high enough to accommodate the removal of the fuel cell.
  3. Loosen the fuel filler neck connecting tube clamp at the tank.
  4. Wrap a shop towel around the fuel filter neck connecting tube and slowly remove the fuel filler neck connecting tube from the fuel tank.
  5. Position a siphon hose into the fuel tank through the fuel filler opening. Place the other end into an approved container with enough capacity to hold the fuel in the tank. Siphon the fuel.
  6. Raise the vehicle to gain access to the fuel tank. Make sure the vehicle is safely supported.






  1. Disconnect the tail pipe hanger attaching bolt.
  2. Remove the muffler hanger attaching bolts and remove the muffler hanger.
  3. Loosen the converter hanger attaching nuts.
  4. Remove the two heat shield attaching screws and note the position for reassembly.
  5. Support the exhaust and move the heat shield to gain the access to the right side of the fuel tank retaining strap attaching bolts.
  6. Remove the in-line fuel filter body clips.
If the nylon fuel feed or return lines becomes kinked, and cannot be straightened, they must be replaced. Do not attempt to repair sections of the nylon fuel lines.
  1. Disconnect the quick-connect fitting at the fuel filter, and return line fitting.
  2. Disconnect the fuel tank electrical connector.
  3. Disconnect the vapor hose at the fuel tank.
  4. Disconnect the vent hose at the fuel tank.




With the aid of an assistant, support the fuel tank, remove the left and right tank retaining strap attaching bolts, and remove the tank.
  1. As necessary, remove the fuel sending unit (which includes the fuel pump), as outlined, in this section.
  2. Then you can change the pump:
  3. Remove the fuel sender assembly.
  4. Disassemble the fuel pump strainer and the fuel pump: Note the position of the strainer in relation to the pump.
  5. See Figure 3


    Fig. 3: Remove the fuel tank locking ring with a non-sparking (brass) punch.


    1. Support the fuel pump in one hand, and grab the strainer in the other hand.
      1. Rotate strainer in one direction and pull off pump. Discard strainer.





      1. Remove deflector.
    1. Disconnect the fuel pump electrical connector.
    2. Loosen the two connecting clamps, if equipped.
    3. Place the fuel sender assembly upside down on the work bench.
      1. Pull the fuel pump downward to remove it from the mounting bracket, then tilt the pump outward and remove it from the connecting hose or the fuel pulse dampener.
    4. It is recommended to replace the hose and clamps, if equipped.
    To install:
    1. Push the fuel pump assembly into the attaching hose. Attach the pump electrical wires and fasten the hose clamps to the attaching hose and around the pump body, where equipped.
    2. Place the fuel tank sender and pump assembly into the fuel tank. Use a new O-ring seal during assembly.
    3. Then put the tank back in:
      1. If the fuel tank is replaced, transfer the fuel feed and return lines from the mounting clips, the vapor hose from the mounting clips and the vent hose from the vent hose fitting.
      2. Check the fuel filler neck for cracks and holes and replace as necessary.
      3. Install the fuel sending unit.
      4. With the aid of an assistant, position and support the fuel tank and install the left and right tank retaining strap attaching bolts and tighten to 18 ft. lbs.
      5. Connect the vent and vapor hoses.
      6. Connect the fuel sending unit electrical connector.
      7. Connect the quick-connect fittings as outlined.
      8. Position the fuel sending unit electrical connector and fuel return line under the in-line fuel filter bracket.
      9. Install the in-line fuel filter and new body clips.
      10. Reposition the heat shield as noted during removal and tighten the retaining screws to 18 lbs. ft.
      11. Tighten the converter hanger attaching bolts to 20 lbs. ft.
      12. Install the muffler hanger and attaching bolts and tighten to 18 lbs. ft.
      13. Install the tailpipe hanger attaching bolt and tighten to 20 lbs. ft.
      14. Lower the vehicle, add fuel and install the fuel filler cap.
      15. Connect the negative battery cable.
      16. Turn the ignition switch to the ON position for 3 seconds, then turn to the OFF position for 5 seconds. Repeat this procedure two or three times to pressurize the system. Again turn the switch to the ON position and check for leaks.

Mar 09, 2011 | 1997 Chevrolet Venture

1 Answer

How do we replace the fuel pump in a 2001 Chevrolet Malibu?


Welcome to Fixya

Here's the procedure on how to install/replace fuel pump for your Chevy malibu.


•1
Raise the rear of the vehicle and place jack stands under the pinch welds on the lower body rocker panel. There are reinforced areas here that are designed to support the weight of the vehicle. Lower the car onto the jack stands and remove the floor jack. Unscrew the fuel filler cap to help relieve pressure that builds up in the tank due to fuel evaporation.
•2
Disconnect the plastic fuel lines leading from the tank to the front of the vehicle by pushing in on the line while depressing the quick disconnect fittings. Unplug the vapor return line and the fuel pump's electrical connector. Remove the fuel filler neck hose by loosening the hose clamps with a screwdriver and prying the hose loose with a large pry bar.
•3
Remove the two rubber exhaust system hangers located near the rear of the exhaust. This will allow the exhaust to move when removing the fuel tank. Remove the metal heat shield from the bottom of the car.
•4
Place the floor jack under the fuel tank, with a large flat piece of wood between the jack and the tank, and lift the tank slightly. This will take the weight of the tank off the straps attaching the tank to the undercarriage of the car. Remove the straps holding the tank to the body of the car, and lower the fuel tank. Slide the fuel tank past the exhaust system, and out from underneath the car.
•5
Remove the fuel pump assembly by turning the spring-loaded retaining ring with the hammer and chisel. Lift the whole assembly out of the fuel tank by lifting the assembly up and then rotating it over to clear the level sensor arm. Unsnap the top, and separate the plastic housing to gain access to the fuel pump. Remove the fuel pump electrical connector, and remove the pump from the assembly by pushing the pump up and over until it clears the assembly.
•6
Install the new pump into the assembly using the new rubber coupler and the new vibration cushion supplied with the pump. Plug the electrical connector into the new pump, and snap the two halves of the plastic housing back together. Install the assembly back into the tank, and rotate the spring-loaded retainer using the hammer and chisel.
•7
Reposition the tank under the car, and lift the tank into place with the floor jack. Install and tighten the retaining straps, heat shield and filler neck hose clamps. Reinstall the exhaust system hangers. Plug the electrical connector back into the assembly. Reconnect the fuel lines and vapor line.
•8
Lower the vehicle off the jack stands and prime the fuel system by cycling the ignition key from off to run a few times. Start the engine and check for leaks

Thank you for using Fixya!

Nov 25, 2010 | 2001 Chevrolet Malibu

2 Answers

Where is the fuel pump on a 1995 Nissan PU


see instructions from AutoZone:
The fuel pump assembly is located in the fuel tank. Refer to the fuel tank assembly illustrations in this section. On most applications, the fuel tank must be lowered to remove the fuel pump assembly. The fuel pump assembly is cooled by the fuel in the tank.

REMOVAL & INSTALLATION


See Figure 1
  1. Before disconnecting the fuel lines or any of the fuel system components, release the fuel system pressure as described previously in this section. Releasing system pressure is a very important step for the correct removal of the electric fuel pump.




0900c1528018d240.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 1: Internal view of the electric fuel pump
  1. Disconnect the negative battery cable. Unfasten the fuel pump assembly electrical connector and remove the fuel tank inspection cover.

If the truck has no fuel tank inspection cover, the fuel tank must be lowered or removed to gain access to the in-tank fuel pump.
  1. Disconnect the fuel outlet and return hoses. Remove the fuel tank assembly, if necessary.
  2. Remove the ring retaining bolts and the O-ring, then lift the fuel pump assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system.

When removing or installing the fuel pump assembly, be careful not to damage or deform it. Always install a new O-ring.
To install:
  1. Install the fuel pump assembly in the fuel tank with a new O-ring. Install the ring retaining bolts. Install the fuel tank if removed.
  2. Reconnect the fuel lines and fasten the electrical connection.
  3. Connect the battery cable, then start the engine and check for fuel leaks.

The "Check Engine Light'' may stay on after installation is completed. If so, the trouble code in the control unit's memory must be erased. To erase the code, disconnect the battery cable for 10 seconds, then reconnect it a verify that the light is extinguished.

TESTING


See Figures 2 and 3
  1. Relieve the fuel system pressure, as described previously in this section.
  2. Disconnect the fuel inlet hose at the electro injection unit.




0900c1528018d241.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 2: Make sure that the fuel line hose clamps are installed properly



0900c1528018d242.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 3: Testing fuel system pressure using a gauge and a "T'' fitting
  1. Install a fuel pressure gauge.
  2. Start the engine and check the fuel line for leakage.
  3. Read the pressure on the pressure gauge. The gauge should read approximately 36.3 psi (250 kPa).
  4. Relieve the fuel system pressure again.
  5. Remove the pressure gauge from the fuel line and reconnect the fuel inlet hose.

Aug 25, 2010 | 1995 Nissan Pickup

1 Answer

Where is the fuel pump located in a 1990 geo prizm? Is it in the fuel tank or on the fuel line?


Electric Fuel Pump REMOVAL & INSTALLATION The electric fuel pump used on fuel injected Nova and Prizm cars is contained within the fuel tank. On 1988–92 models it cannot be removed without removing the tank from the car. NOTE: Before removing fuel system parts, clean them with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent. CAUTION
The fuel injection system is under pressure. Refer to the procedure above and release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times. 1988–92
  1. Release the fuel system pressure as outlined earlier.
  2. Using a siphon or pump, drain the fuel from the tank and store it in a proper metal container with a tight cap.
  3. Remove the rear seat cushion to gain access to the electrical wiring.
  4. Disconnect the fuel pump and sending unit wiring at the connector.
  5. Raise the vehicle and safely support it on jackstands.
  6. Loosen the clamp and remove the filler neck and overflow pipe from the tank.
  7. Remove the supply hose from the tank. Wrap a rag around the fitting to collect escaping fuel. Disconnect the breather hose from the tank, again using a rag to control spillage.
  8. Cover or plug the end of each disconnected line to keep dirt out and fuel in.
  9. Support the fuel tank with a floor jack or transmission jack. Use a broad piece of wood to distribute the load. Be careful not to deform the bottom of the tank.
  10. Remove the fuel tank support strap bolts.
  11. Swing the straps away from the tank and lower the jack. Balance the tank with your other hand or have a helper assist you. The tank is bulky and may have some fuel left in it. If its balance changes suddenly, the tank may fall.
  12. Remove the fuel filler pipe extension, the breather pipe assembly and the sending unit assembly. Keep these items in a clean, protected area away from the car.
  13. To remove the electric fuel pump:
    1. Disconnect the 2 pump-to-harness wires.
    2. Loosen the pump outlet hose clamp at the bracket pipe.
    3. Remove the pump from the bracket and the outlet hose from the bracket pipe.
    4. Separate the outlet hose and the filter from the pump.
  14. While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank. Clean the inside of the tank with water and a light detergent and rinse the tank thoroughly several times.
  15. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions. To install:
  16. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  17. Assemble the outlet hose and filter onto the pump; then attach the pump to the bracket.
  18. Connect the outlet hose clamp to the bracket pipe and connect the pump wiring to the harness wire.
  19. Install the fuel pump and bracket assembly onto the tank.
  20. Install the sending unit assembly.
  21. Connect the breather pipe assembly and the filler pipe extension. NOTE: Tighten the breather pipe screw to 17 inch lbs. and all other attaching screws to 30 inch lbs.
  22. Place the fuel tank on the jack and elevate it into place within the car. Attach the straps and install the strap bolts, tightening them to 29 ft. lbs.
  23. Connect the breather hose to the tank pipe, the return hose to the tank pipe and the supply hose to its tank pipe. tighten the supply hose fitting to 21 ft. lbs.
  24. Connect the filler neck and overflow pipe to the tank. Make sure the clamps are properly seated and secure.
  25. Lower the vehicle to the ground.
  26. Connect the pump and sending unit electrical connectors to the harness.
  27. Install the rear seat cushion.
  28. Using a funnel, pour the fuel that was drained from its container into the fuel filler.
  29. Install the fuel filler cap.
  30. Start the engine and check carefully for any sign of leakage around the tank and lines. Fig. 1: Fuel tank components — 1988 VIN Code 5 engine (Nova) 84225048.gif
    Fig. 2: Fuel tank components — 1989–92 84225049.gif

Aug 14, 2010 | 1990 Geo Prizm

3 Answers

How do you replace fuel pump 1993 camry


1992-96 Models

Be sure this procedure is done in a well ventilated area.
  1. Disconnect the negative battery cable.
  2. Relieve the fuel pressure.
  3. Remove the rear seat cushion.
  4. Remove the floor service hole cover.
  5. Disconnect the electrical fuel pump wiring at the fuel pump assembly. Check for any fuel leakage while in there.

5b4fccc.jpg

Fig. 6: Pull back the rug under the rear seat to access the fuel pump and sending unit cover
  1. Remove the gas cap, this will prevent any fuel gas spilling out of any high pressure lines.
  2. Using SST 09631-22020 or an equivalent line (flare nut) wrench, disconnect the outlet

pipe from the pump bracket.
  1. Remove the pump bracket attaching screws.
  2. Disconnect the return hoses from the pump bracket, then pull out the pump/bracket assembly.
  3. Remove the nut and spring washer, then disconnect the wires from the pump bracket.
  4. Remove the sending unit attaching screws, then remove the unit from the bracket.
  5. Pull the lower side of the fuel pump from the bracket.
  6. Unplug the connector to the fuel pump.
  7. Disconnect the hose from the pump.
  8. Separate the filter from the pump. Use a small screwdriver to remove the attaching clip.
  9. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
  10. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.

To install:
  1. Install the pump filter using a new clip. Install the rubber cushion under the filter.
  2. Connect the outlet hose to the pump, then attach the pump to the bracket and tighten to 22-25 ft. lbs. (29-34 Nm).
  3. Engage the connector to the fuel pump.
  4. Install the fuel sending unit to the pump bracket.
  5. Install the fuel pump and bracket assembly onto the tank. Use new gaskets. Tighten the pump bracket retaining screws to 34 inch lbs. (4 Nm).
  6. Connect the return hoses to the pump bracket.
  7. Install the service hole cover, then the engage the fuel pump and sending unit connector.
  8. Install the rear seat cushion.
  9. Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.

Hope this help (remember comment and rated this).

Apr 09, 2010 | 1992 Oldsmobile Cutlass

1 Answer

How do I change 88 seville fuel pump


The pump is located in the fuel tank. Tank must be dropped to gain access & you do that by removing the staps & carefully lowering the tank. On top of the tank, the retaining ring has to be removed, hoses disconnected carefully, and the entire fuel pump assembly with the float & low fuel warning sensor (if equipped) will be removed .

Important to note the position of the hoses, wiring, and the mounting position of the pump and the retaining ring as it fits into the tank. Mark items to identify where to return them to once done. Pictures with a digital camera are good to have when needing to review how things were.

Not a bad idea to replace the in-line fuel filter when replacing the fuel pump assembly, fill it as full as possible with fuel injector cleaner before reinstalling the hoses & you'll get a good injector cleaning as well.


good luck

Feb 14, 2010 | 1988 Cadillac Seville

1 Answer

How to replace fuel pump 91 lesabre


Removal & Installation The fuel pump is located in the fuel tank. The fuel tank must be removed from the vehicle in order to access the pump.
  1. Properly relieve fuel system pressure.
  2. If not already done, disconnect the negative battery cable.
  3. Raise and safely support the vehicle.
  4. Safely drain and remove the fuel tank assembly, as outlined later in this section.
  5. If necessary, detach the quick-connect fittings from the fuel sender assembly and remove the fuel lines.
  6. Remove the fuel gauge sender and pump assembly by turning the cam locking ring counterclockwise. It may be necessary to use a spanner wrench, such as tool J-24187, to perform this.
  7. Carefully lift the assembly from the fuel tank, then remove the fuel pump from the fuel gauge sender unit.
  8. Remove the sender O-ring from the top of the sender and discard.
  9. Disconnect the pump wires, hose clamps and the clamp from around the pump body.
  10. Pull the pump assembly out of the rubber connectors.
  11. Inspect the fuel pump attaching hose for any signs of deterioration, and replace as necessary.
  12. To install:
    1. Push the fuel pump assembly into the attaching hose. Attach the pump electrical wires and fasten the hose clamps to the attaching hose and around the pump body.
    2. Place the fuel tank sender and pump assembly into the fuel tank. Use a new O-ring seal during assembly.
    3. Place the cam lock over the assembly, then lock by turning clockwise, using a suitable spanner wrench, if necessary.
    4. If removed, attach the fuel sender fuel line quick-connect fittings.
    When installing the fuel tank, make sure all rubber sound isolators or anti-squeak spacers are replaced in their original locations.
    1. Install the fuel tank, as outlined later in this section.
    2. Refill the fuel tank.
    3. Connect the negative battery cable.
    4. Turn the ignition switch to the ON position to pressurize the fuel system and check for leaks.

Oct 10, 2009 | 1991 Buick LeSabre

2 Answers

I am not getting fuel to my engine


Removal
  1. Relieve the Fuel System Pressure . Refer to the procedure in this section.
Cushion Cover and Pad, Rear Seat — One-Piece and 50/50 Split Fold Removal
  1. Remove the two rear seat cushion bolts.
  1. Fold the rear seat back cover and cushion (60084) forward.
  1. Carefully pull the rear seat cushion and cover (60030) out from under the rear seat back cover and cushion and remove the rear seat cushion and cover from the vehicle
  1. Remove the rear seat cushion and cover (60030). Refer to Section 01-10 for the removal procedure.
  1. Remove the three luggage compartment floor cover hold-down pins and fold the luggage compartment floor cover (45455) forward until the fuel pump assembly access plate is visible.
  1. Remove the four fuel pump assembly access plate screws, the ground lead, and the fuel pump assembly access plate from the chassis.




  1. Disconnect the fuel pump assembly electrical connector.




  1. On 4-door vehicles, remove the fuel vapor tube shutoff valve bolt and the evaporative emission tube shut off valve (9G332) from the bracket on the fuel pump assembly housing.




  1. Loosen the two hose clamps and disconnect the two fuel pump hoses from the fuel pump hose fittings on the fuel pump assembly housing.




  1. Remove the four screws (2-door) or eight screws (4-door) and lift the fuel pump assembly housing from the fuel tank (9002).




  1. Disconnect the fuel level sensor electrical connector.
  1. Remove the two fuel level sensor washers and fuel level sensor nuts and the fuel level sensor.



-------------------------------------------------------------------------------------
Section 10-01: Fuel Tank, Filters, Lines and Electric Fuel Pump 1996 Aspire Workshop Manual
REMOVAL AND INSTALLATION Fuel Pump Removal
  1. Remove the fuel level sensor. Refer to the Fuel Level Sensor removal procedure in this section.
  1. Remove the fuel pump screw, fuel pump grommet and the fuel pump bracket from the bottom of the fuel pump (9350).




  1. Remove the fuel tank sender filter bracket, fuel tank sender filter (9A011) and the fuel tank sender filter retainer from the fuel pump.
  1. Disconnect the fuel pump electrical connector.
  1. Remove the clamp and the fuel pump from the fuel pump assembly housing.

Apr 19, 2009 | 1995 Ford Aspire

2 Answers

1999 jeep cherokee do you have to remove the fuel pump to replace


The combination Fuel Filter/Fuel Pressure Regulator is located on the fuel pump module. The fuel pump module is located on top of fuel tank.

The filter/regulator may be removed without removing fuel pump module although fuel tank must be removed.

REMOVAL
  1. Remove fuel tank. Refer to Fuel Tank Removal/Installation.
  2. Clean area around filter/regulator.
  3. Disconnect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.
  4. Remove retainer clamp from top of filter/regulator. Clamp snaps to tabs on pump module. Discard old clamp.
  5. Pry filter/regulator from top of pump module with 2 screwdrivers. Unit is snapped into module
  6. Discard gasket below filter/regulator.
    1. Before discarding filter/regulator assembly, inspect assembly to verify that O-rings are intact. If the smallest of the two O-rings can not be found on bottom of filter/regulator, it may be necessary to remove it from the fuel inlet passage in fuel pump module.
    INSTALLATION
    1. Clean recessed area in pump module where filter/regulator is to be installed.
    2. Obtain new filter/regulator (two new O-rings should already be installed)
    3. Apply a small amount of clean engine oil to O-rings. Do not install O-rings separately into fuel pump module. They will be damaged when installing filter/regulator.
    4. Install new gasket to top of fuel pump module.
    5. Press new filter/regulator into top of pump module until it snaps into position (a positive click must be heard or felt).
    6. The arrow molded into top of fuel pump module should be pointed towards front of vehicle (12 O'clock position).
    7. Rotate filter/regulator until fuel supply tube (fitting) is pointed towards front of vehicle (12 O'clock position).
    8. Install new retainer clamp (clamp snaps over top of filter/regulator and locks to flanges on pump module).
    9. Connect fuel line at filter/regulator. Refer to Quick-Connect Fittings for procedures.
    10. Install fuel tank. Refer to Fuel Tank Removal/Installation.
WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK .

Two different procedures may be used to drain fuel tank (lowering tank or using DRB scan tool).

The quickest draining procedure involves lowering the fuel tank.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump is not operating, tank must be lowered for fuel draining. Refer to following procedures.

FUEL TANK REMOVAL
  1. Disconnect negative battery cable at battery.
  2. Release fuel system pressure. Refer to the Fuel System Pressure Release.
  3. Raise and support vehicle.
  4. If Equipped: Remove fuel tank skid plate.
  5. Remove 4 fuel hose shield mounting bolts and remove fuel hose shield from body.
    1. Remove fuel tank fill hose and vent hose clamps at fuel tank filler tube. Remove both hoses at fuel filler tube.
    2. Remove exhaust tailpipe heat shield mounting bolts and remove shield. CAUTION: To protect fuel tank from exhaust heat, this shield must reinstalled after tank installation.
    3. Place a hydraulic jack to bottom of fuel tank. WARNING: PLACE A SHOP TOWEL AROUND FUEL LINES TO CATCH ANY EXCESS FUEL .
      1. Disconnect fuel supply line from fuel extension line near front of fuel tank. Refer to Fuel Tubes/Lines/Hoses and Clamps. Also refer to Quick-Connect Fittings for procedures.
      2. Disconnect EVAP canister vent line near front of tank.
      3. Disconnect fuel pump module electrical connector (pigtail harness) near front of tank. Harness connector is clipped to body.
        1. Remove two fuel tank strap nuts. Position both tank support straps away from tank.
        2. Carefully lower right side of tank while feeding both fuel hoses through access hole in body. Fuel Tank Full And Not Drained Using DRB Scan Tool: To prevent fuel loss through hoses, keep left side of tank higher than right side while lowering. Do not allow hose openings to drop lower than top of tank.
        3. Continue lowering tank until clear of vehicle. Place tank on floor with left side (hose side) higher than right side
          1. Drain tank by removing fuel fill hose at tank. Fuel fill hose is largest of 2 hoses. Insert the drain hose (from an approved gasoline draining station) into hose opening. Drain tank until empty.
          2. If fuel pump module removal is necessary, refer to Fuel Pump Module Removal/installation for procedures.
          INSTALLATION
          1. If fuel pump module is being installed, refer to Fuel Pump Module Removal/installation for procedures.
          2. Install fuel fill/vent hoses to tank fittings. To prevent hose from kinking, rotate each hose until index mark on hose is aligned to index tang on fuel tank.
          3. Install hose clamps to hoses. Position clamps between index marks on each hose.
          4. Position fuel tank to hydraulic jack.
          5. Raise tank into position while guiding fuel fill and vent hoses into and through access hole in body.
          6. Continue raising tank until positioned to body.
          7. Attach two fuel tank mounting straps and mounting nuts. Tighten nuts to 10 Nm (90 in. lbs.) torque. Do not over tighten nuts.
          8. Install both fuel hoses to fuel fill tube. Tighten both retaining clamps.
          9. Position fuel hose shield to body. Install and tighten 4 mounting bolts.
          10. Connect fuel pump module pigtail harness electrical connector near front of tank.
          11. Connect fuel pump module supply line near front of tank. Refer to Quick-Connect Fittings for procedures.
          12. Connect EVAP hose near front of tank.
          13. Install exhaust tailpipe heat shield.
          1. Install fuel tank skid plate (if equipped).
          1. Lower vehicle and connect battery cable to battery.

Feb 08, 2009 | 1999 Jeep Cherokee

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