Fuel Pump

This procedure removes and replaces the fuel pump module by lowering the fuel tank on a 2017 Maserati Levante with 3.0L V6 Twin Turbo engine.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM Maserati specification
• Fuel pump module O-ring seal × 1 — Usually included with pump assembly
• Fuel tank strap hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface in well-ventilated area away from ignition sources
2. Ensure fuel tank is less than 1/4 full. If more than 1/4 full, siphon fuel into approved safety containers before beginning
3. Disconnect negative battery cable and isolate to prevent accidental reconnection
4. Remove rear seat cushion by releasing forward clips to access fuel pump connector
5. Disconnect fuel pump electrical connector under rear seat
6. Start engine and allow to run until it stalls to deplete fuel line pressure (engine will not start if already disconnected)
7. Attempt to start engine 2-3 additional times to ensure pressure is relieved
8. Raise vehicle on lift or securely support on jack stands at all four corners
9. Place Class B fire extinguisher within immediate reach
10. Wear safety glasses and nitrile gloves throughout entire procedure

Procedure

1. 1

   Verify fuel pressure relief
   Connect fuel pressure gauge to the Schrader test port on the fuel rail (located on driver side of engine). Verify pressure reads 0 PSI. If pressure remains, do not proceed until cause is identified. The fuel pump connector must be disconnected and engine run to depletion.
   ⚠️Do not proceed if fuel pressure is present. Pressurized fuel will spray when lines are disconnected.
2. 2

   Access fuel tank from underneath
   From underneath vehicle, locate the fuel tank positioned between rear axle and rear subframe. Identify the fuel supply line, fuel return line, EVAP lines, and fuel tank filler neck. Note routing and positions for reassembly. Clean area around fuel line connections with shop towels to prevent dirt contamination.
3. 3

   Disconnect fuel filler neck
   Locate the fuel filler neck hose connection at the fuel tank inlet. Loosen hose clamp and carefully slide hose off the tank inlet pipe. Be prepared for residual fuel spillage. Use drain pan to catch fuel. Disconnect EVAP vent line from filler neck area using appropriate quick-disconnect tool.
4. 4

   Disconnect fuel lines and electrical
   Using fuel line disconnect tools, release the quick-connect fittings on the fuel supply and return lines at the tank. Press the release tabs and pull lines straight off to avoid damage. Cap or plug all open lines immediately to prevent contamination. Disconnect any remaining EVAP lines from the tank using quick-disconnect tools. If not already done from above, disconnect main fuel pump electrical connector.
5. 5

   Support fuel tank
   Position a floor jack with rubber pad or transmission jack underneath the center of the fuel tank. Raise jack until it just makes contact with tank, supporting the weight but not lifting. Ensure jack is stable and tank is balanced on the jack pad.
   ⚠️Fuel tank with residual fuel weighs 40-80 lbs. Ensure jack is properly positioned and stable before removing straps. Tank will drop suddenly if not supported.
6. 6

   Remove tank strap bolts
   Locate the two fuel tank retaining straps. Remove the bolts securing each strap to the vehicle chassis using appropriate socket. The straps are hinged at the forward end. Remove bolts from the rear mounting points first. Note: Bolts may be corroded; use penetrating oil if needed. Keep track of any washers or spacers.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
7. 7

   Lower fuel tank
   Slowly and carefully lower the jack to drop the fuel tank approximately 6-8 inches. Lower only enough to access the top of the tank where fuel pump module is mounted. Verify all lines and electrical connections are disconnected before lowering. If resistance is felt, stop and check for missed connections.
   ⚠Do not fully remove tank unless necessary. Lowering 6-8 inches provides sufficient access while keeping tank stable and manageable.
8. 8

   Clean fuel pump module area
   With tank lowered, the top surface is now accessible. Clean the area around the fuel pump module lock ring thoroughly using shop towels and non-sparking wire brush. Remove all dirt and debris to prevent contamination from entering tank when module is removed.
9. 9

   Remove fuel pump lock ring
   Using the fuel pump lock ring spanner tool, engage the tool into the notches of the lock ring. Rotate the lock ring counterclockwise (left) to unthread it from the tank. The lock ring has left-hand threads. Once loose, carefully lift lock ring off. Be prepared for fuel spillage as seal breaks.
   ⚠Lock ring has LEFT-HAND THREADS. Turn counterclockwise to loosen. Do not use hammers or chisels which can create sparks.
   Torque spec

   Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
10. 10

    Remove fuel pump module
    Carefully lift the fuel pump module assembly straight up and out of the tank opening. Tilt module slightly to angle the fuel level sender arm through the opening. Fuel will drain from module; hold over drain pan. Once clear of tank, place module in drain pan. Note orientation of module for installation of replacement.
    ⚠Fuel level sender arm is fragile. Avoid bending or striking arm during removal.
11. 11

    Remove and inspect O-ring seal
    Remove the old O-ring seal from the groove in the fuel tank opening. Inspect the sealing surface on the tank for damage, corrosion, or debris. Clean the sealing surface thoroughly with shop towels. Any debris or damage to sealing surface can cause fuel leaks.
12. 12

    Install new fuel pump module
    Install new O-ring seal (typically included with new pump) into the groove on fuel tank opening. Lightly lubricate O-ring with clean gasoline. Orient new fuel pump module in same position as original, ensuring fuel level sender arm is positioned correctly. Carefully lower module into tank opening, tilting to feed sender arm through. Press module fully down until it seats against O-ring.
    ℹ️Do not use petroleum-based lubricants on O-ring. Use only gasoline or approved fuel system lubricant.
13. 13

    Install and torque lock ring
    Place lock ring over fuel pump module and engage threads. Using lock ring spanner tool, rotate clockwise (right) to tighten. Remember that lock ring has left-hand threads, so clockwise tightens. Torque lock ring to specification using torque wrench and spanner tool. Ensure lock ring is fully seated and torqued evenly.
    ⚠️CRITICAL: Proper torque on lock ring is essential for fuel-tight seal. Under-torque causes leaks; over-torque damages threads. Use calibrated torque wrench.
    Torque spec

    Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
14. 14

    Raise and secure fuel tank
    Raise the floor jack to lift fuel tank back into position against vehicle underbody. Ensure tank aligns properly with mounting points. Swing tank straps into position and install strap bolts. Start all bolts by hand before tightening. Torque tank strap bolts to specification in a cross pattern to ensure even pressure.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
15. 15

    Reconnect all lines and electrical
    Reconnect fuel supply and return lines to tank fittings, ensuring quick-connects fully engage with audible click. Tug on each line to verify secure connection. Reconnect all EVAP lines to tank. Reconnect fuel filler neck hose and secure with hose clamp. Reconnect fuel pump electrical connector either from underneath or from interior under rear seat. Verify all connections are secure and properly routed.

Reassembly

1. Double-check all fuel line connections are secure with audible clicks on quick-connects
2. Verify all electrical connectors are fully seated and locked
3. Lower vehicle from lift or jack stands
4. Reconnect negative battery cable
5. Reinstall rear seat cushion if removed

Verification

• Before starting engine, cycle ignition key to ON position (without starting) 3-4 times, waiting 5 seconds between cycles. This primes fuel system and allows pump to build pressure
• Inspect underneath vehicle for any fuel leaks at tank connections, pump module seal, and all line connections while ignition is ON
• Start engine and allow to idle. Immediately check for leaks at all connections and pump module seal
• With engine running, verify no fuel odor in cabin or around vehicle
• Check fuel gauge operation to confirm fuel level sender is functioning
• Test drive vehicle and verify normal fuel system operation with no hesitation or fuel delivery issues
• After test drive, perform final leak inspection of all fuel connections while engine is hot
• If ANY fuel leaks are detected, immediately shut off engine, relieve fuel pressure, and correct the issue before operating vehicle

More procedures for this vehicle