Replaced Fuel Pump

[Trail X]

I tackled the job of replacing the fuel pump yesterday as both a preventative maintenance item, and to fix that infernal empty fuel level gauge.

I used other very helpful writeups on Trailvoy, so I figured I would post their links here. At first I had found the 2003 writeup only. When I got my fuel pump in, I started sweating bullets because my pump didn't look like the one in the pictures. Luckily I found the 2005 writeup, with the pump that looked like mine. I do not know the years for the different pumps, but I would check rock auto to figure out which you need to order.

2003: http://forums.trailvoy.com/showthread.php?t=47921

2005: http://forums.trailvoy.com/showthread.php?t=77929

Being an off-road vehicle, I ran into the issue of a ton of mud caked on top of my fuel pump. So cleaning that area added a bit of time. The best method for me seemed to be water, and lots of it. I used a 5 gallon bucket and doused the pump. Then to dry it I used a reversed shop vac.

The quick-connectors for the fuel and evap lines were rather tricky. I found that the first step was to push the lines together as hard as possible to relieve pressure on the plastic clips. Then, squeeze the 'button' on the connector as hard as possible. I found a screwdriver shaft between my thumb and the button worked better than my thumb itself (Though I still have sore thumbs today). Once the clip is 'unclipped', mine still wouldn't want go let go, so it was all about getting your hands in there, rotating and pulling with as much force as possible. In retrospect, I'm wondering if some liquid wrench would have helped. There were a total of 8 'quick' connectors to undo on my 2005. Only a couple of those came easy. Putting them back together was fairly uneventful. The factory manual says to use a couple drops of oil on the male end to help ensure a good connection.

The fuel filler connection was also a nightmare. There is no good way to get leverage on this tube. The trick I found was to first run a screwdriver down between the metal filler pipe and the connecting hose to help release the top of this tube. Then I squirted liquid wrench into both sides of the connection. Once I did that, the hose would rotate fairly freely, but the flanges on the connections wouldn't really let the hose go. So I found rotating and bending the crap out of this connection seemed to be about the only way.

To drop and raise the tank is really a two person job. One person needs to control the jack, while the other person needs to be under the vehicle releasing/connecting the electronic connections and guiding the tank into place. Luckily my wife gave me a hand, working the jack. Without that, I'd still be trying to hug that stupid tank into place.

In all, it took me about 5 and a half hours.

I didn't do a good job documenting it because others have already done so. Just a few pictures showing the poor condition of my stock pump and the new one.

If you're doing this job yourself, feel free to ask any questions.

[rgraboske]

Just a quick question, how often do you change your fuel filter? I replace mine every 20K miles, and it's always been fairly easy to get out.

[djthumper]

Just a quick question, how often do you change your fuel filter? I replace mine every 20K miles, and it's always been fairly easy to get out.

On the earlier models you didn't have to drop the tank to replace the fuel filter. I believe it was 05 and newer we have to drop the tank to access it since it is on top of the tank. So mine isn't going to get replaced just because.

[Trail X]

The fuel filter on the 05 is not a serviceable item. It's built into the fuel pump SA. I should have taken pictures, but the pump has a line out going to a filter, which then goes to the output.

[djthumper]

Well that just makes it even more of a PITA and pricey thing to do.

[rgraboske]

The fuel filter on the 05 is not a serviceable item. It's built into the fuel pump SA. I should have taken pictures, but the pump has a line out going to a filter, which then goes to the output.

Ah.........

I love it when they make things not servicable