Fuel Pump: Service and Repair

1. Relieve fuel system pressure as described under "Precautions, Fuel System Pressure Relief".
2. Disconnect battery ground cable, then remove battery cover and the battery.
3. Remove boot floor carpet and boot front liner.
4. Remove left and right boot side liners.
5. Remove fuel filler aperture housing.
6. Raise and support vehicle, then remove fuel tank as follows:
a. Empty fuel tank into gasoline container. Remove retaining clips securing fuel feed and return hoses.
b. Disconnect hoses from fuel tank. Remove and discard sealing rings from hoses.
c. Plug all fuel tank openings. Lower vehicle, then remove spare wheel mounting bracket.
d. Cut and remove ratchet strap securing fuel pump link harness to harnesses and ground leads.
e. Cut and remove ratchet straps securing harnesses to fuel tank retaining straps.
f. Remove retaining clip securing ride level harness to battery tray. Disconnect battery tray drain tube.
g. Release and remove bolts securing battery tray to body.
h. Reposition battery tray to lay on its side to allow tank removal.
i. Reposition tank retaining straps upward for access and secure to boot aperture flange with adhesive tape.
j. Remove tank upper sound insulation pad. Note position and disconnect cables from fuel gauge tank sender unit.
k. Disconnect fuel pump link lead from evaporative loss flange connection.
l. Reposition harness downward below tank level. Cut and remove ratchet strap securing filler aperture housing drain tube to filler neck.
m. Release vapor pipe hose to underbody pipe securing clip. Disconnect vapor pipe/hose assembly from underbody pipe.
n. Remove vapor pipe hose from evaporative flange by release clip and pulling hose from evaporative loss flange stub pipe.
o. Remove over-pressure pipe from evaporative flange by pushing back collar on quickfit connector in flange port and pulling pipe from connector.
p. Remove fuel tank assembly.

7. Remove evaporative loss flange and sealing ring.
8. Using hose clip removal tool No. JD175, or equivalent, loosen hose clip securing internal fuel return hose to the fuel pump module fuel return connection.
9. Disconnect fuel return hose from fuel pump module.
10. Lift fuel pump module mounting rubber off steel support bracket tabs.
11. Remove fuel pump module and mounting rubber from fuel tank.
12. Cut and remove ratchet strap securing mounting rubber to fuel pump module.
13. Repeat procedure to remove second fuel pump.
14. Reverse procedure to install, noting the following:
a. Tighten to specifications.
b. Ensure tangs on fuel pump module and mounting support bracket tabs are aligned correctly.
c. Ensure feed and return hoses are fully seated on fuel pump module and tank pipes.