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Fuel Pump

Powertrain Management › Fuel Delivery and Air Induction
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartFuel Pump
ManufacturerCHY
OEM part #RL004095AB
Price$404.00
NotesIncludes: Fuel Tank Sending Unit.

Labor

Replace1.4 hr
Warranty 0.0 hrSkill B
Procedures
Fuel Pump Module - Removal9 steps
⚠ 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.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
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  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ 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.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
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  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Fuel Pump: Testing and Inspection14 steps
⚠ WARNING
Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure.
⚠ WARNING
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
⚠ WARNING
To reduce the risk of fire and possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard.
⚠ WARNING
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury.
△ CAUTION
Stop All Actuations.
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  1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes -Repair or replace as necessary. -Perform the PCM VERIFICATION TEST. Powertrain Verification Test. No -Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM THE GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A
  2. Turn the ignition off.
  3. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail.
  4. Install the appropriate Fuel Line Adapters / Fitting from the Gas and Diesel Fuel Pressure/Decay Tester. Proceed -Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY
  5. Connect the Gas and Diesel Fuel Pressure/Decay Tester , Fuel Inlet Hose (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting.
  6. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5).
  7. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3). Proceed -Go To 4 4. CHECK FUEL PRESSURE Perform the following procedure to purge air from the system: -Open the Fuel System Isolation Valve (1). -Close the Flow Test Valve (2). -Ignition on, engine not running. -With the scan tool, actuate the fuel pump. -Open the Flow Test Valve (1) for 10 seconds, then close the Valve. -CAUTION: Stop All Actuations. -Turn the ignition off. -Disconnect, empty and then reconnect the Reservoir Assembly.
  8. Turn the ignition on, wait five seconds, turn the ignition off and then wait one minute before proceeding.
  9. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 kPa +/- 34 kPa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 kPa +/- 34 kPa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes -Go To 5 No - Checking The Fuel Delivery System Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. 5. CHECK FUEL DELIVERY SYSTEM OUTPUT
  10. Ignition on, engine not running.
  11. With the scan tool, actuate the fuel pump.
  12. Open the Flow Test Valve (1) for 20 seconds, then close the Valve.
  13. Turn the ignition off.
  14. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output specification is ml/s x 20 seconds = fuel flow in ml. Does the amount of fuel in the reservoir meet or exceed the specification? Yes -Test complete. No - Checking The Fuel Delivery System Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
FUEL PUMP
The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component.
FUEL PUMP
Voltage to operate the electric pump is supplied through the fuel pump relay.
Fuel is drawn in through a filter at the bottom of the module and pushed through the electric motor gearset to the pump outlet.
Check Valve Operation: The fuel pump module contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors.Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine off) is a normal condition.
The electric fuel pump is not a separate, serviceable component.
MODULE-FUEL PUMP
FUEL PUMP MODULE📷 1
WARNING: The fuel system is under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released. (Refer to FUEL SYSTEM PRESSURE RELEASE procedure )
1. Drain and remove fuel tank. (Refer to REMOVAL ). 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position special Lockring Remover/Installer tool 9340 (3) into notches on outside edge of lock ring (5). 4. Install 1/2 inch drive breaker bar (1) to special Lockring Remover/Installer tool 9340 (3). 5. Rotate breaker bar counterclockwise to remove lockring. 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing.
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FUEL PUMP MODULE📷 1
CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.
1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. 4. Install Lockring Remover/Installer 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Lockring Remover/Installer 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank.
RAIL-FUEL
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REMOVAL - 3.7L📷 4
WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released.
1 - MOUNTING BOLTS (4) 2 - QUICK-CONNECT FITTING 3 - FUEL RAIL 4 - INJ. #1 5 - INJ. #3 6 - INJ. #5 7 - INJ. #2 8 - INJ. #4 9 - INJ. #6 10 - CONNECTOR TUBE
CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to
separate rail halves at connector tube (10). Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube.
1. Remove fuel tank filler tube cap. 2. Perform Fuel System Pressure Release Procedure. See FUEL SYSTEM PRESSURE RELEASE. 3. Remove negative battery cable at battery. 4. Remove air duct at throttle body air box. 5. Remove air box at throttle body. 6. Disconnect fuel line latch clip and fuel line at fuel rail. A special tool will be necessary for fuel line disconnection. See STANDARD PROCEDURE. 7. Remove necessary vacuum/vapor lines at throttle body.
8. Disconnect electrical connectors at all 6 fuel injectors. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal.
9. Disconnect electrical connectors at throttle body sensors. 10. Remove 6 ignition coils. Refer to REMOVAL .
1 - MOUNTING BOLTS (4) 2 - QUICK-CONNECT FITTING 3 - FUEL RAIL 4 - INJ. #1 5 - INJ. #3 6 - INJ. #5 7 - INJ. #2 8 - INJ. #4 9 - INJ. #6
10 - CONNECTOR TUBE
11. Remove four fuel rail mounting bolts (1). 12. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in cylinder head. Gently rock and pull right side of rail until injectors just start to clear cylinder head holes. Repeat this procedure (left/right) until all injectors have cleared cylinder head holes. 13. Remove fuel rail (with injectors attached) from engine. 14. If fuel injectors are to be removed, see REMOVAL.
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MOTOR - FUEL PUMP

Description

An engine mounted, low-pressure mechanical fuel pump is not used with the 2.8L diesel engine.
An electric fuel pump is mounted to the fuel pump module. The pump supplies a low-pressure fuel supply to the engine.
Fuel is drawn in through a filter at the bottom of the module and pushed through the electric motor gearset to the pump outlet.
The electric fuel pump is not a separate, serviceable component. The entire fuel pump module must be replaced.
MODULE - FUEL PUMP📷 2

Removal

1
The 2.8L diesel fuel pump module (2) is located on the top of fuel tank.
2
Drain and remove fuel tank.
3
Note rotational position of module before attempting removal. An indexing arrow is located on top of
module for this purpose.
4
Position special Lockring Remover/Installer tool 9340 (3) into notches on outside edge of lockring (5).
5
Install 1/2 inch drive breaker bar (1) to special Lockring Remover/Installer tool 9340 (3).
6
Rotate breaker bar counterclockwise to remove lockring.
7
Remove lockring. The module will spring up slightly when lockring is removed.
8
Remove module from fuel tank. Be careful not to bend float arm while removing.

Installation

CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced.
1
Using a new seal (gasket), position fuel pump module into opening in fuel tank.
2
Position lockring (5) over top of fuel pump module.
3
Rotate module until embossed alignment arrow points to center alignment mark. This step must be
performed to prevent float from contacting side of fuel tank.
4
Install Lockring Remover/Installer 9340 (3) to lockring.
5
Install 1/2 inch drive breaker (1) into Lockring Remover/Installer 9340 (3).
6
Tighten lockring (clockwise) until all seven notches have engaged.
7
Install fuel tank.
PUMP-FUEL INJECTION
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