in-tank pump module. The Powertrain Control Mod-
ule (PCM) controls the operation of the fuel system
by providing battery voltage to the fuel pump
through the fuel pump relay. The PCM requires only
three inputs and a good ground to operate the fuel
pump relay. The three inputs are:

• Ignition voltage

• Crankshaft Position (CKP) sensor

• Camshaft Position (CMP) sensor

DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM

(Refer to Appropriate Diagnostic Information)

STANDARD PROCEDURE

STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE

(1) Remove Fuel Pump relay from Power Distribu-

tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.

(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no

longer run.

(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC’s)

may have been stored in PCM memory due to fuel
pump relay removal. The DRB III

t scan tool must be

used to erase a DTC.

STANDARD PROCEDURE - DRAINING FUEL
TANK

Two different procedures may be used to drain fuel

tank (lowering tank or using DRBIII

t scan tool).

The quickest draining procedure involves lowering

the fuel tank.

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE

SERVICING

THE

VEHICLE.

THIS

MAY

RESULT IN PERSONAL INJURY OR DEATH.

As an alternative procedure, the electric fuel pump

may be activated allowing tank to be drained at fuel
rail connection. Refer to DRBIII

t 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 in this
group for procedures. Disconnect the fuel line at the
fuel rail and remove the plastic retainer from the

fuel rail. Take plastic retainer and install it back into
the fuel line from body. Check the O-ring and make
sure that it is in place and not damaged. Attach end
of special test hose tool number 6539 at fuel line con-
nection from the body line. Position opposite end of
this hose tool to an approved gasoline draining sta-
tion. Activate fuel pump and drain tank until empty.
When done remove the special test hose tool number
6539 from the body line. Remove the plastic retainer
from the special test hose tool number 6539 and rein-
stall it into the fuel line from the body. Check the
O-ring and make sure that it is in place and not
damaged. Install the fuel line to the fuel rail.

If electric fuel pump is not operating, tank must be

lowered for fuel draining. Refer to following proce-
dures.

(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-

cedure.

(3) Disconnect negative cable from battery.
(4) Raise vehicle and support.
(5) Certain models are equipped with a separate

grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.

(6) Open fuel fill door and remove screws mount-

ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.

(7) Place a transmission jack under center of fuel

tank. Apply a slight amount of pressure to fuel tank
with transmission jack.

(8) Remove fuel tank mounting straps.
(9) Lower the tank just enough so that the

filler tube fitting is the highest point of the fuel
tank.

(10) Remove filler tube from fuel tank. Tank will

be drained through this fitting.

NOTE: WRAP SHOP TOWELS AROUND HOSES TO
CATCH ANY GASOLINE SPILLAGE.

(11) Drain fuel tank into holding tank or a prop-

erly labeled Gasoline safety container.

WARNING: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.

(12) If fuel pump module removal is necessary,

refer to Fuel Pump Module Removal/Installation in
this section.

14 - 2

FUEL DELIVERY

FUEL DELIVERY (Continued)

SPECIFICATIONS

TORQUE

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Fuel Tank Straps

39.8

Filler Tube Ground Strap

7.5

Filler Tube Screws

2.3

Fuel Filler Tube Clamp

3.6

31.8

Fuel Rail to Intake

Manifold 4-Cylinder

11.9

105

Fuel Rail to Cylinder Head

4-Cylinder

195

Fuel Rail to Intake

Manifold 2.7L

11.9

105

FUEL SYSTEM PRESSURE

400 kpa ±34 kpa (58 psi ± 5 psi)

SPECIAL TOOLS

FUEL

Pressure Gauge Assembly C–4799–B

Fuel Pressure Test Adapter 6539

Spanner Wrench 6856

Fuel Line Adapter 1/4

O2S (Oxygen Sensor) Remover/Installer—C-4907

FUEL DELIVERY

14 - 3

FUEL DELIVERY (Continued)

FUEL LEVEL SENDING UNIT /
SENSOR

DESCRIPTION

The fuel gauge level sending unit is attached to the

side of fuel pump module. The level sensor is a vari-
able resistor.

OPERATION

Its resistance changes with the amount of fuel in

the tank. The float arm attached to the sensor moves
as the fuel level changes.

The fuel level input is used as an input for OBD II.

If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.

REMOVAL

Remove fuel pump module. Refer to Fuel Pump

Module in this section.

(1) Depress retaining tab and remove the fuel

pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 1) and
(Fig. 2).

(2) Pull off locking wedge (Fig. 3).
(3) Using a small screwdriver lift locking finger

away from terminal and push level sensor and
ground terminals out of connector (Fig. 4).

(4) Use screwdriver to move locking tab on level

sensor and move level sensor down channel to
remove (Fig. 5) and (Fig. 6).

(5) Slide level sensor out of installation channel in

module.

INSTALLATION

(1) Insert level sensor wires into bottom of opening

in module.

(2) Wrap wires into groove in back of level sensor.
(3) While feeding wires into guide grooves, slide

level sensor up into channel until it snaps into place.
Ensure tab at bottom of sensor locks in place.

(4) Install level sensor wires in connector. Push

the wires up through the connector and then pull
them down until they lock in place. Ensure signal

and ground wires are installed in the correct posi-
tion.

(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump

module electrical connector.

(7) Install fuel pump module. Refer to Fuel Pump

Module in this section.

O2S (Oxygen Sensor) Remover/Installer - 8439

Fig. 1 ELECTRICAL CONNECTOR

Fig. 2 Fuel Pump/Level Sensor Electrical Connector

1 - RETAINING TAB
2 - ELECTRICAL CONNECTOR

14 - 4

FUEL DELIVERY

FUEL DELIVERY (Continued)

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