Product Overview
The Delphi FG0808 Fuel Module is engineered with 80 years of OE heritage, ensuring high quality and precise fitment for vehicle applications. This manual provides essential information for the proper installation, operation, and maintenance of your Delphi FG0808 Fuel Module.
Key Features
- Part is validated, tested, and matched to the correct vehicle application.
- Delphi brings 80 years of OE Heritage into each Delphi assembly, ensuring quality and fitment for each Delphi part.
- Rigorous OE-testing ensures the pump can withstand extreme temperatures.
- Accurate and responsive detection ensures precise fuel gauge readings.
- Quiet and efficient fuel delivery.
- Precision-machined for easy installation.
- Long-lasting, corrosion-resistant design with a tight, leak-free seal.
Figure 1: Main view of the Delphi FG0808 Fuel Module.
Safety Precautions
Always ensure the vehicle is on a stable, level surface and properly supported before beginning any work. Disconnect the vehicle's battery to prevent electrical hazards. Wear appropriate personal protective equipment, including safety glasses and gloves. Fuel is highly flammable; ensure adequate ventilation and have a fire extinguisher nearby. Do not smoke or work near open flames or sources of ignition. Always relieve fuel system pressure prior to opening fuel systems. Releasing fuel under pressure can cause fire and injury. Store fuel in an approved container like a gas caddy or gas can.
Preparation for Installation
Before starting the installation, ensure the fuel tank is as low as possible to minimize weight and fuel spillage. Gather all necessary tools and replacement parts. Inspect the new Delphi FG0808 Fuel Module for any signs of damage or defects prior to installation.
Tools Required (Recommended)
- Socket wrench set (8mm, 15mm)
- Hose pick tool
- Brass punch
- Rubber mallet
- Fuel tank jack/support
- Fuel collection bucket
- Compressed air (for cleaning)
- Penetrating oil
- Clean rags
Installation Guide
1. Relieve Fuel System Pressure
Open the fuel door and remove the fuel cap. Locate the fuel pump relay in the under-hood fuse box (refer to your vehicle's owner's manual for exact location). Remove the fuel pump relay. Attempt to start the vehicle; it may crank but not start, or start and then stall. This depressurizes the fuel system. Once the vehicle fails to start, replace the fuel pump relay and close the fuse box cover.
Video 1: This segment demonstrates how to locate and remove the fuel pump relay to depressurize the fuel system before proceeding with the fuel module replacement. (Source: 1A Auto, Inc)
2. Disconnect Fuel Lines and Electrical Connections (Rear)
Safely raise and support the vehicle. Locate the fuel lines near the rear differential. Disconnect the EVAP hose by squeezing its two tabs and pulling it off. Loosen the 8mm clamp on the fuel fill hose and carefully pry it off the filler neck tube using a hose pick. Disconnect the blue locking clamp on the other EVAP line by pressing it in and pulling the line off.
Video 2: This segment shows how to disconnect the EVAP system hose from the fuel tank. (Source: 1A Auto, Inc)
Video 3: This segment illustrates loosening the clamp and removing the fuel fill hose from the filler neck tube. (Source: 1A Auto, Inc)
Video 4: This segment demonstrates how to disconnect the EVAP canister line by pressing the locking tabs. (Source: 1A Auto, Inc)
3. Disconnect Fuel Lines and Electrical Connections (Top of Tank)
Locate the electrical harnesses and fuel lines on top of the fuel sending unit. Disconnect the two electrical connectors by pressing their locking tabs and pulling them away. For the larger connector, use a small screwdriver or pick to gently pry out the gray locking tab before disconnecting. Disconnect the remaining fuel lines by squeezing their tabs (or using long-nose pliers) and pulling them off the fuel sending unit.
Video 5: This segment shows how to disconnect the electrical harnesses from the fuel sending unit. (Source: 1A Auto, Inc)
Video 6: This segment demonstrates disconnecting the fuel lines from the top of the fuel sending unit. (Source: 1A Auto, Inc)
4. Remove Fuel Tank Straps and Lower Tank
Apply pressure underneath the fuel tank using a jack or suitable support. Remove the 15mm bolts holding the front and rear fuel tank straps in place. Carefully lower the fuel tank, pulling it rearward slightly to clear the cross member. Ensure all lines and cables are disconnected before fully lowering the tank.
Video 7: This segment shows the removal of the rear fuel tank strap bolt. (Source: 1A Auto, Inc)
Video 8: This segment shows the removal of the forward fuel tank strap bolt. (Source: 1A Auto, Inc)
Video 9: This segment demonstrates carefully lowering the fuel tank, ensuring it clears the cross member. (Source: 1A Auto, Inc)
5. Remove Old Fuel Pump Module
Once the fuel tank is on the ground, clean any dirt and debris from around the fuel sending unit to prevent contamination. Apply penetrating oil to the metal locking ring. Use a brass punch and a rubber mallet to turn the metal locking ring counter-clockwise until it loosens. Carefully lift the old fuel pump module out of the tank, paying attention to the float arm and any remaining fuel.
Video 10: This segment shows the importance of cleaning the area around the fuel sending unit before removal. (Source: 1A Auto, Inc)
Video 11: This segment demonstrates using a brass punch and rubber mallet to loosen and remove the fuel sending unit locking ring. (Source: 1A Auto, Inc)
Video 12: This segment shows the careful removal of the old fuel pump module from the fuel tank. (Source: 1A Auto, Inc)
6. Install New Fuel Pump Module
Transfer any necessary plastic pieces or components from the old module to the new Delphi FG0808 Fuel Module, inspecting them for damage. Install the new fuel pump module into the tank, ensuring the float arm is positioned correctly. Place the new sealing gasket into the groove around the opening. Install the metal locking ring and tighten it clockwise using the brass punch and rubber mallet until it is securely seated all the way around.
Video 13: This segment shows how to transfer small plastic components from the old module to the new one. (Source: 1A Auto, Inc)
Video 14: This segment demonstrates carefully inserting the new fuel pump module into the tank. (Source: 1A Auto, Inc)
Video 15: This segment shows the installation of the new gasket and the locking ring for the fuel pump module. (Source: 1A Auto, Inc)
Video 16: This segment demonstrates tightening the locking ring securely using a brass punch and rubber mallet. (Source: 1A Auto, Inc)
7. Reconnect Fuel Lines and Electrical Connections (Top of Tank)
Reconnect the fuel lines and electrical harnesses to the new fuel pump module. Ensure each connection clicks securely into place and give a gentle tug to confirm it is properly seated.
Video 17: This segment shows the reconnection of the fuel lines and electrical harnesses to the new fuel pump module. (Source: 1A Auto, Inc)
8. Raise Fuel Tank and Reconnect Fuel Lines (Rear)
Carefully raise the fuel tank back into position, ensuring the forward end goes in first and clears the cross member. Reconnect the fuel fill hose and tighten its clamp. Reconnect the EVAP hoses, ensuring they click into place.
Video 18: This segment demonstrates carefully raising the fuel tank back into its original position. (Source: 1A Auto, Inc)
Video 19: This segment shows the reconnection of the fuel fill hose and tightening its clamp. (Source: 1A Auto, Inc)
Video 20: This segment shows the reconnection of the EVAP lines to the fuel tank. (Source: 1A Auto, Inc)
9. Reinstall Fuel Tank Straps
Reinstall the fuel tank straps, ensuring they are properly aligned. Insert and tighten the 15mm mounting bolts for both the front and rear straps until they are snug and secure.
Video 21: This segment shows the reinstallation and tightening of the rear fuel tank strap. (Source: 1A Auto, Inc)
Video 22: This segment shows the reinstallation and tightening of the forward fuel tank strap. (Source: 1A Auto, Inc)
10. Final Checks
Remove the support from under the vehicle and lower it safely. Replace the fuel cap and close the fuel door. Start the vehicle and check for any fuel leaks. Allow the engine to run for a few minutes to ensure proper operation and fuel pressure. Take the vehicle for a short road test to confirm everything is functioning correctly.
Video 23: This segment shows the final step of replacing the fuel cap and closing the fuel door. (Source: 1A Auto, Inc)
Video 24: This segment demonstrates starting the vehicle and performing a final check for fuel leaks and proper operation. (Source: 1A Auto, Inc)
Operating Instructions
The Delphi FG0808 Fuel Module is designed for reliable fuel delivery. Ensure your vehicle's fuel tank always contains an adequate amount of fuel to prevent damage to the fuel pump. Regularly monitor your fuel gauge for accurate readings.
Maintenance Guidelines
Fuel Tank Cleaning
It is recommended to periodically check and clean the fuel tank to avoid contamination that can affect the fuel pump's performance and longevity. If replacing the fuel pump, always clean the fuel tank thoroughly before installing the new module.
Video 25: This official Delphi video provides a comprehensive guide on how to properly clean your vehicle's fuel tank, a crucial step for maintaining fuel system health. (Source: PHINIA Delphi USA LLC)
General Checks
- Regularly inspect fuel lines and connections for any signs of leaks or damage.
- Ensure the fuel cap is securely tightened after refueling to prevent contamination and maintain proper fuel system pressure.
- Address any unusual noises from the fuel pump area promptly.
Troubleshooting Common Issues
Engine Cranks but Won't Start
This could indicate low or no fuel pressure. Check the fuel pump relay and ensure there is fuel in the tank. If the issue persists after replacing the fuel pump, further diagnosis of the fuel system (e.g., fuel pressure regulator, fuel filter) may be required.
Inaccurate Fuel Gauge Readings
The Delphi FG0808 Fuel Module includes a precise oil level sensor. If readings are inaccurate, inspect the float arm and sensor for any obstructions or damage. Ensure electrical connections to the sensor are secure.
Fuel Leaks
Immediately address any fuel leaks. Check all fuel line connections, the fuel pump module's sealing gasket, and the integrity of the fuel tank itself. Fuel leaks pose a significant fire hazard.
Product Specifications
| Feature | Detail |
|---|---|
| Brand | Delphi |
| Model | FG0808 |
| Fit Type | Vehicle Specific Fit |
| Vehicle Service Type | Car, Truck |
| Item Dimensions (L x W x H) | 15.7 x 8.2 x 8.2 inches |
| Material | Metal |
| Item Weight | 4 Pounds |
| Style | Gerotor |
| Gas Type | Gasoline |
| Mounting Type | Tank Mount |
| Operation Mode | Mechanical |
| UPC | 689604197936 |
| OEM Part Numbers | AFS0956S, RE0956S, E3581M, E3747M, MU1639, TS1016, A30154, 19168126, 19207716, 19256621, 19370394, 88965386, 88965556, DFG0808, 1AMFP00029, SP6025M, P76262M, M2317576, 67442 |
Package Contents
- Fuel Pump Module Assembly
Warranty and Support
For warranty information or technical support, please refer to the official Delphi website or contact your authorized Delphi dealer. Always use the appropriate shop manual for your vehicle to obtain specific instructions. If you do not have an installation manual or enough skills to install this part, it is recommended that you seek help from a qualified mechanic.
