This procedure removes and replaces the fuel pump assembly by accessing it through the rear seat area, requiring fuel system depressurization and careful handling of flammable materials.

Warnings

Tools required

Parts

• Fuel pump assembly × 1 — 77020-06260 or equivalent
• Fuel pump seal/gasket × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/2 full. If necessary, siphon fuel using approved equipment into approved containers before beginning work.
2. Park vehicle on level ground in a well-ventilated outdoor area or shop with active ventilation.
3. Turn ignition off and remove key. Ensure all accessories are off.
4. Disconnect negative battery terminal and wait 90 seconds before proceeding.
5. Allow engine to cool completely if recently driven (minimum 2 hours).
6. Gather all required tools and parts before beginning. Verify fuel pump lock ring tool compatibility.
7. Have Class B fire extinguisher within reach and verify it is properly charged.
8. Put on chemical-resistant gloves and safety glasses.

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump relay or fuse in the engine bay fuse box (check owner's manual for exact location, typically labeled EFI or FUEL PUMP). Remove the relay/fuse. Reconnect battery negative terminal temporarily. Attempt to start the engine and let it run until it stalls from fuel starvation (typically 5-15 seconds). Crank engine for an additional 5 seconds after stalling to ensure complete depressurization. Turn ignition off. Disconnect negative battery terminal again and verify it remains disconnected.
   ⚠️This is a critical safety step. Skipping or improperly performing fuel pressure relief can cause fuel to spray under pressure during disassembly.
2. 2

   Remove rear seat cushion
   Access the rear passenger compartment. Locate two seat cushion retaining clips at the front lower edge of the rear seat bottom cushion. Push down firmly on the seat cushion front edge and pull upward simultaneously to disengage the clips. Lift the seat cushion up and forward to remove it from the vehicle. Set aside in a clean area.
3. 3

   Remove fuel pump access cover
   Locate the rectangular access cover in the floor pan beneath where the rear seat was positioned (driver's side). The cover is secured by 4-6 Phillips screws. Remove all screws and carefully lift the access cover. You should now see the fuel pump module assembly with fuel lines and electrical connector attached. Clean any debris from the area using a vacuum to prevent contamination from entering the fuel tank.
   ⚠Do not allow dirt or debris to fall into the fuel tank opening. Contamination can damage the new fuel pump or fuel injectors.
4. 4

   Disconnect electrical connector
   Locate the electrical connector attached to the top of the fuel pump module. Press the locking tab and pull the connector straight up to disconnect. Move the connector away from the work area to prevent damage.
5. 5

   Disconnect fuel lines
   Identify the fuel supply line and fuel return line connected to the pump module (typically quick-connect fittings). Place shop towels around the connections to catch residual fuel. Using the appropriate fuel line disconnect tool, depress the tabs on each quick-connect fitting and pull the lines straight off. Cap or plug the fuel lines to prevent contamination and additional fuel spillage. Note the orientation of each line for reassembly.
   ⚠Expect residual fuel to drain from lines. Have towels ready and drain into fuel-safe container.
6. 6

   Remove fuel pump lock ring
   Clean the area around the lock ring thoroughly with shop towels. Position the fuel pump lock ring tool onto the lock ring tabs. The lock ring turns counterclockwise to loosen. Apply steady force with the tool to break the ring free, then unscrew it completely by hand. Remove the lock ring and set aside. Note: Some fuel may spill during this step.
   ⚠️Do not use impact tools, hammers, or create sparks near the fuel tank opening. Use only the proper lock ring tool with smooth, controlled force.
   Torque spec

   Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
7. 7

   Remove fuel pump assembly
   Carefully lift the fuel pump module assembly straight up and out of the tank. The assembly includes a fuel level sender arm that must be angled carefully to avoid bending. Tilt the assembly as needed to clear the opening while keeping it as vertical as possible. Once clear, tilt the assembly over the fuel tank opening to drain residual fuel back into the tank. Place the old assembly into a fuel-safe drain pan.
   ⚠The fuel level sender arm is fragile. Bending it will cause inaccurate fuel gauge readings. Handle with care.
8. 8

   Inspect and clean tank opening
   Inspect the fuel tank opening and sealing surface for debris, corrosion, or damage. Clean the sealing surface with a clean, lint-free cloth. Inspect the fuel tank interior (use flashlight) for excessive debris or contamination. If significant contamination is present, the tank should be professionally cleaned before installing the new pump.
9. 9

   Prepare new fuel pump assembly
   Remove the new fuel pump assembly from packaging. Install the new seal/gasket onto the pump module flange, ensuring it is properly seated in the groove. Verify all components are properly attached and that no shipping protectors or tags remain on the assembly. Inspect the fuel level sender arm to ensure it moves freely and is not damaged.
10. 10

    Install new fuel pump assembly
    Carefully lower the new fuel pump assembly into the fuel tank opening. Align the assembly so the fuel level sender arm enters at the correct angle to avoid bending. Ensure the alignment marks or tabs on the pump module align with corresponding marks on the tank opening. Press the assembly down until it seats fully against the seal. Verify the seal is not pinched or displaced.
    ⚠Proper alignment is critical. The pump module will only seat correctly in one orientation. Do not force it.
11. 11

    Install and torque lock ring
    Place the lock ring onto the fuel pump module threads. Thread it clockwise by hand until snug. Using the fuel pump lock ring tool and torque wrench, tighten the lock ring to the specified torque value. Verify the lock ring is fully seated and the pump module does not rotate.
    ⚠️CRITICAL TORQUE: Under-torquing can cause fuel leaks and fire hazard. Over-torquing can damage the tank flange. Use a calibrated torque wrench.
    Torque spec

    Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
12. 12

    Reconnect fuel lines
    Install new O-rings on the fuel line connections if not already installed. Push each fuel line onto its corresponding connection on the pump module until you hear and feel a distinct click. Gently tug on each line to verify it is fully locked. Ensure lines are routed correctly and not kinked or pinched.
13. 13

    Reconnect electrical connector
    Align the electrical connector with the pump module terminal and push firmly until it clicks into place. Verify the locking tab is fully engaged. Gently pull on the connector to confirm it is secure.
14. 14

    Reinstall access cover and rear seat
    Position the access cover over the opening, aligning all screw holes. Install all screws and torque to specification in a cross-pattern. Reinstall the rear seat cushion by inserting the rear hooks first, then pressing down firmly on the front edge until both retaining clips engage with an audible click.

Reassembly

1. Reconnect the negative battery terminal and tighten securely.
2. Do not start the engine yet. Turn the ignition key to ON position (without cranking) for 2 seconds, then OFF. Repeat this cycle 4-5 times to allow the fuel pump to prime the system and build pressure.
3. Inspect the fuel pump access area and all connections for any signs of fuel leakage before proceeding.

Verification

• With the ignition in ON position, listen for the fuel pump to run for approximately 2 seconds then stop. This confirms electrical operation.
• Start the engine and allow it to idle. Listen for smooth operation without sputtering or hesitation.
• Check fuel gauge operation to verify fuel level sender is functioning correctly.
• With engine running, inspect all fuel connections at the pump module (visible from access opening if cover is temporarily removed) for any signs of leakage. Immediately shut off engine if any leak is detected.
• Reinstall access cover fully if not already done. Test drive the vehicle and monitor for proper fuel delivery, smooth acceleration, and accurate fuel gauge reading.
• After test drive, verify no fuel odor is present in the passenger compartment and re-inspect all work areas for leaks.

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