Fuel Pump: Service and Repair

NOTE: Wrap shop towels around fuel filler hoses to catch any fuel spill.

1. Disconnect battery ground cable then remove fuel tank cap.

Fuel Pressure Regulator Location:

Fuel Pressure Release Procedure - Typical:

2. Release fuel system pressure as follows:
a. Remove the negative battery cable, and remove the fuel tank fill cap.
b. Place sufficient shop towels under the pressure test port (schrader valve) on the fuel rail.
c. Remove the cap from the pressure test port on the fuel rail.
d. Using an appropriate fuel pressure gauge hose, place one end of hose in an approved container and screw the other end of the hose onto the test port to relieve fuel pressure. Absorb any spilled fuel with shop towels.
e. Install cap on test port.

3. If fuel pump works, drain fuel through supply hose.
4. If fuel pump does not work and fuel level is lower than filler hose, disconnect filler neck and siphon fuel through filler hose.
5. If fuel pump does not work and tank is full, drain fuel from neck as follows:
a. Support fuel tank with suitable transmission jack, then loosen fuel tank mounting straps (passenger side fuel mounting strap slightly more than driver side).
b. Lower tank slightly, then loosen filler neck-hose clamp and slide back on hose.
c. Disconnect hose from neck and drain tank through hose.
6. Raise and support vehicle, then disconnect all vent and filler hoses.
7. Remove vent hoses from hose routing bracket at top of frame rail, then place transmission jack under center of fuel tank and apply slight pressure.
8. Remove nuts from two mounting straps inboard ends and lower tank far enough to disconnected fuel pump module electrical connector.
9. Disconnect fuel supply and return lines from fuel pump, then fuel vapor line from pressure relief/rollover valve.
10. Lower tank from vehicle.
11. Note direction of fuel filter/pressure regulator, pressure relief/rollover valve and electrical connector, then remove pump lock nut and module will spring up.
12. Remove fuel pump being careful not to bend wire rod connecting float to module.
13. Reverse procedure to install, ensuring proper alignment of module with retaining bracket on bottom of tank. Tighten bolts to specifications.