to hold the fuel pump and any fuel it
may contain.

Due to the design of the fuel pump
assembly it must be carefully
removed so it will not be
damaged.

b) Slowly pull up on the upper portion of the assembly until it clears the tank.

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c) Slide the upper portion to the left until the lower portion of the assembly is centered in the service port.
NOTE: DO NOT bend the arm for the sending unit. Avoid spilling any fuel.

d) Pull out the lower portion of the assembly as shown.
NOTE: DO NOT force the lower portion from the tank as it could be damaged.

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e) Slowly remove the assembly until the sending unit lightly touches the tank.

f)

Tilt the assembly to remove it from the tank and place it in the container.
NOTE: Place the assembly in the container immediately after removal to prevent leakage of fuel
into the vehicle.

g) Remove and discard the tank O-ring.

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h) Place a plastic bag over the fuel tank opening
and secure with the original retaining ring.

7. REPLACING THE PUMP
a) Tilt the assembly and drain the fuel into the
container.
NOTE: Dispose of the fuel in accordance
with local regulations.

Video

b) Disconnect the harness 3 connectors.

c) Disconnect the 3 harness clamps.
NOTE: DO NOT damage the claws.
Disconnect the harness one claw at a time
so that the harness cover is not damaged.

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d) Disengage the claw and slide the fuel sender
upward with the harness.
NOTE: DO NOT bend the fuel sender arm

e) Disengage the claws to disconnect the hose
from the sub-tank.

f) Disengage the hose support from the claw.
g) Disengage the hose from the sub-tank by
pulling it upward.

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h) Disengage the 2 claws and remove the fuel filter and pump.
NOTE: DO NOT damage the claws

i)

Disengage the 5 claws and separate the
pump from the suction plate.
NOTE: DO NOT damage the claws

j) Remove and discard the O-ring.
k) Remove the spacer.
DO NOT discard the spacer it will
be reused
l)

Discard the fuel pump in accordance with
local regulations.

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8. INSTALL THE NEW FUEL PUMP
a) Reinstall the spacer.
NOTE: The spacer is non-directional.
b) Lubricate the new O-ring with gasoline and
install it on the convex portion of the new
pump.

NOTE: DO NOT drop the new pump. If
dropped replace it with a new one.
Always use a new O-ring to prevent
starting issues.
DO NOT install the O-ring on the
concave area of the pump.

c) Rubricate the new O-ring and install the new
pump onto the lower suction plate.

d) Reengage the 5 claws by pushing the pump
and suction plate tougher as shown.

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e) Reengage the 2 claws for the pump to the
sub-tank.
NOTE: DO NOT damage the claws

f)

Connect the hose support to the sub-tank by
pushing down.
g) Fasten the hose to the claw.

h) Connect the hose connection to the sub-tank.

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i) Remove the covers from the sending unit.
j) Remove and discard the harness.
k) Install the new harness onto the sending unit.

l)

Reinstall the sending unit by sliding the unit
down onto the sub-tank and reengaging the
claw.
NOTE: DO NOT bend the sending unit arm

m) Reconnect the 3 connectors.

n) Engage the 2 harness’s for the sending unit
with the clamp and ensure that they are not
too tight or loose at the terminals.
NOTE: DO NOT damage the claws
Engage the harness one by one to
avoid damaging the covers

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o) Engage the 4 harness’s with the clamp and
ensure that the harness is correctly tensioned
at the upper connection as shown.
NOTE: DO NOT engage the harness cover into
the clamp.

p) Engage the 4 harnesses into the clamp and ensure that the harness has the correct tension.

9. REINSTALL THE FUEL PUMP ASSEMBLY
a) Remove the ring and plastic bag from the
tank.
b) Discard the old retaining ring.

c) Clean the area of the tank where the new
gasket will be installed.

Video

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d) Mark the starting point of the threads, on the fuel tank on the floor as shown.

e) Install the new gasket.

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f)

Reinstall the pump assembly.
NOTE: Ensure that the pump assembly is correctly oriented. DO NOT twist the assembly during
installation.

g) Insert the lower portion of the pump
assembly.
NOTE: DO NOT bend the sender arm

h) Slide the assembly to the left and insert the
upper portion into the tank.

10. INSTALL THE NEW RETAINING RING
a) Temporarily place the claws evenly around
the NEW retaining ring.
NOTE: Ensure that a new ring is used.
DO NOT place the retaining ring on
the tank prior to preforming steps.
Ensure that the lower edge of the
claw is under the retainer.

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b) Place the SST on 2 of the claws as shown
and temporarily install the round plates and
bolts.

c) Temporarily install the other 2 round plates
and bolts.

d) Ensure that the center of the SST plate is
centered on the fuel pump assembly.
NOTE: Ensure that the round plates are
correctly engaged into the SST
plate.

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e) Tighten the 4 bolts that attach the claws to
the SST plate.
NOTE: Ensure that the claws are
perpendicular to the SST plate.

f)

Remove the protective cap for the fuel line if
equipped.

g) Spray a small amount of silicon into a tray.
NOTE: Ensure you spray the silicon into
the tray outside of the vehicle so
the vapors are not distributed in
the cabin.

39

h) Carefully apply the silicon to the inner lip of the new retaining ring.
NOTE: DO NOT lubricate the threads.
The silicon is applied to lubricate the contact area between the ring and the pump assembly.

i)

Apply silicon to the top of the pump assembly
in the area shown.
NOTE: DO NOT spray silicon on top of the
pump assembly.

j)

Check that the gasket is in the correct
position.

40

k) Align the tabs of the pump assembly and the
fuel tank. Then push down and hold the pump
assembly in place.
NOTE: A second person may be needed to
tighten the ring.

l)

Set and align the retainer (area with the short ribs) to the starting point of the tank threads as shown.

m) While pressing down on the pump assembly tighten the retaining ring approximately 90 degrees.

41

n) Press down on the left rear of the retaining ring to ensure that the threads are properly engaged.

o) Use a vainer caliper to verify that the ring is
properly engaged.
1. Place the caliper on the top of the ring
and measure to the top of the tank as
shown.
2. Take measurement at 3 different points
around the ring.

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3. Compare the 3 measurements.
If the difference between the 3
measurements is less than 3 mm the ring
is properly set.
If the difference between measurements
is approximately 6 mm then the ring is
NOT properly set.
NOTE: If the ring is not properly set
remove ring and return to install the
retaining ring.

p) After ensuring that the ring is properly set. Push down on the top of the pump assembly and turn the ring 1
turn (360 degrees)

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q) Release the top of the pump assembly and slowly rotate they ring approximately 90 degrees, until the ring
lines up with the marks on the tank as shown.

r)

Use a vernier caliper to verify that the ring is
properly seated.
1. Place the caliper on the top of the ring and
measure to the top of the tank as shown.
2. Take measurement at 3 different points
around the ring

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3.

Compare the 3 measurements.
If the difference between the 3
measurements is less than 3 mm the ring
is properly set.
If the difference between measurements
is approximately 6 mm then the ring is
NOT properly set.

NOTE: If the ring is not properly set
remove ring and return to install the
retaining ring.

11. RECONNECT THE FUEL LINE
a) Remove the bag from the fuel line.
b) Check that the line is clean and not damaged.
c) Reconnect the line by pushing straight down.
d) Reinstall the clip.

e) Push and pull on the line to ensure it is
securely connected.

45

12. REPLACE BUTYL TAPE
a) Remove any tape from around the service
port.
b) Remove the old butyl tape from around the
service port.

c) Apply new butyl tape around the service port
as shown ensuring that the end overlapped
by 15mm.
NOTE: Ensure that the height of the tape
is at least 6mm

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d) Reconnect the fuel pump connector.
NOTE: DO NOT install the cover until the
vehicle has been leak checked
e) Reinstall the fuel tank cap

f)

Use compressed air to clear the cabin of fuel
vapors.
g) Reconnect the negative battery cable.

13. CHECK FUEL PUMP OPERATION
a) Connect Techstream
b) Turn IG on (engine off)
c) Using Techstream go to
Powertrain
Engine and ECT
Active Test
Control the Fuel Pump Speed

47

d) Check that the fuel pump is operating.
NOTE; If the fuel pump is inoperative
recheck connections
e) Check the fuel line and area around the
retaining ring for leaks.
NOTE: Repair any leaks found

f)

Check that the current fuel gauge reading
matches the recorded value from:
Section VII step 3.
g) Check and clear DTC’s
h) Shut down vehicle.

i)

Check that the area around the service
port is clean.

j)

Reinstall the harness grommet if needed.

k) Align the match marks for the service port
cover and reinstall the cover by pressing
it onto the floor.

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14. REINSTALL INTERIOR TRIM
a) Reinstall the LF cowl trim board by
reengaging the claw and clip.
b) Reinstall the plastic nut.

c) Reinstall the LF scuff plate by reengaging the
7 claws and 4 clips.

15. REINSTALL REAR SEAT CUSHION
a) Reengage the 2 hooks into the seat back.
b) Insert the seat belts through the openings in
the cushion.
c) Reengage the 2 hooks on the front edge of
the cushion.
If the plastic locks for the front
hooks come out of the floor pan
they will need to be replaced.

d) Check that the seatbelts operate and lock into
the buckles correctly.

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e) Close the access door for the battery.
f) Reinstall the truck mat.

g) Return the front seats to their original
position.
h) Perform any needed system intializations.

−
−

◄ VERIFY REPAIR QUALITY ►
Confirm that there are no fuel leaks
Confirm that there are no DTC’s
If you have any questions regarding this update, please contact your area representative.

X. APPENDIX
A. Fuel Tank Draining
1. DRAINING THE FUEL TANK
NOTE: Ensure that the battery is fully charged. DO
NOT charge the battery while draining fuel.
DO NOT drain from the filler neck the hose
could become stuck in the tank inlet valve.

a) Remove the rear seat cushion see:
Section VII Step 2
b) Remove the service port cover see:
Section VII Step 5
c) Disconnect the fuel line see:
Section IX Step 3

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d) Connect a hose to the fuel pump outlet.
NOTE: Hose ID 6mm

e) Connect the other end of the hose to an appropriate
fuel container or into the filler neck of another
vehicle.

f) Connect Techstream
g) Turn IG on (engine off)
h) Using Techstream go to
Powertrain
Engine and ECT
Active Test
Control the Fuel Pump Speed
NOTE: The fuel tank capacity is 55 liters.
Fuel pump output is depended upon battery
charge and is approximately 1 liter per
minute.
DO NOT abandon the vehicle while draining
the tank

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A. CAMPAIGN DESIGNATION DECODER

E

L

Year Campaign is Launched Repair Phase

8 = 2008
9 = 2009
A = 2010
B = 2011
C = 2012
D = 2013
E = 2014
F = 2015
Etc...

0 = Remedy
1 = Prelim/Interim
2 = Prelim/Interim for
Phase 2 Vehicles
(Remedy not yet
available) “1 or 2” will
change to “0” when the
Remedy is available

A
Current Campaign Letter
for this year

1st Campaign = A
2nd Campaign = B
Etc...

B. CAMPAIGN PARTS DISPOSAL
As required by Federal Regulations, please make sure all campaign parts (original parts) removed from the
vehicle are disposed of in a manner in which they will not be reused, unless requested for parts recovery
return.

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