Fuel Pressure Release: Service and Repair

Fuel System Pressure Release

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: The Fuel Pump Control Module (FPCM) is located on the frame rail above the spare tire.
Disconnect the Fuel Pump Control Module (FPCM) electrical connector.






3. Start the engine and allow it to idle until it stalls.

4. After the engine stalls, crank the engine for approximately 5 seconds to make sure the fuel rail pressure has been released.

5. Turn the ignition switch to the OFF position.

6. Disconnect battery ground cable.

Gasoline Turbocharged Direct Injection (GTDI) equipped vehicles

7. Remove and discard the nut for the high pressure fuel tube bracket.

8. NOTE: On vehicles equipped with Gasoline Turbocharged Direct Injection (GTDI), it is necessary to release the high pressure fuel system prior to disconnecting a low pressure fuel tube quick connect coupling.
NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the flare nut with a shop towel to absorb any residual fuel pressure during the loosening of the flare nut.
Disconnect the high pressure fuel tube-to-fuel injection pump flare nut to release the fuel pressure.


9. Connect the high pressure fuel tube-to-fuel injection pump flare nut.
1. Tighten to 15 Nm (133 lb-in).

2. Tighten an additional 30 degrees.

3. Tighten to 32 Nm (24 lb-ft).


All vehicles

10. Install new nut for the high pressure fuel tube bracket.
- Tighten to 8 Nm (71 lb-in).






11. Reconnect battery ground cable.

12. When fuel system service is complete, reconnect the FPCM (Fuel Pump Control Module) electrical connector.





13. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before starting the engine.


14. Start the vehicle and check the fuel system for leaks.