Fuel Pump: Service and Repair

REMOVAL

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.

1. Drain and remove fuel tank.

Fig. 19 Fuel Pump Module:

Fig. 20 Fuel Pump Module - 35 Gallon Fuel Tank:

Fig. 21 Locknut Removal/Installation - Typical:

2. The plastic fuel pump module locknut is threaded onto fuel tank (Fig. 19) or (Fig. 20). Install Special Tool 6856 to locknut and remove locknut (Fig. 21). The fuel pump module will spring up when lock nut is removed.
3. Remove module from fuel tank.

INSTALLATION

CAUTION: Whenever the fuel pump module is serviced, the rubber gasket must be replaced.

1. Using a new gasket, position fuel pump module into opening in fuel tank.
2. Position locknut over top of fuel pump module. Install locknut finger tight.

Fig. 22 Fuel Pump Module - 26 Or 34 Gallon Fuel Tank:

Fig. 23 Fuel Pump Module - 35 Gallon Fuel Tank:

3. Rotate module until positioned as shown in (Fig. 22) or (Fig. 23). This step must be performed to prevent float from contacting side of fuel tank. Be sure fuel filter/fuel pressure regulator is pointed to drivers side of vehicle.

Fig. 24 Locknut Removal/Installation - Typical:

4. Install Special Tool 6856 (Fig. 24) to locknut.
5. Tighten locknut to 24-44 Nm (18-32 ft. lbs.) torque.
6. Install fuel tank.