Fuel Pump: Service and Repair

CAUTION: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced. The fuel system on these vehicles is depressurized by disconnecting the inertia switch and cranking the vehicle for a minimum of 15 seconds.

REMOVAL
1. Place vehicle on hoist, do not raise.

2. Depressurize fuel system as outlined.
3. Remove fuel from fuel tank by pumping out through filler. Use care to prevent combustion from fuel spillage.
4. Raise vehicle on hoist.

5. Disconnect and remove fuel filler tube.

6. Support fuel tank and remove fuel tank support straps. Lower fuel tank partially and remove fuel lines, electrical connectors, and vent lines from tank. Remove fuel tank to bench.

7. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during procedures.

8. Turn the fuel pump locking ring counterclockwise with the fuel tank lock ring wrench tool and remove locking ring.
9. Remove the fuel pump and bracket assembly.

10. Remove seal gasket and discard.

INSTALLATION
1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.
2. Put a light coating of grease on a new seal ring to hold it in place during assembly and install it in the fuel ring groove.
3. Install fuel pump and sender assembly carefully to ensure that the filter is not damaged. Be sure that the locating keys are in keyways and the seal ring remains in place.
4. Hold the fuel sender and sealing gasket in place, install and rotate the locking ring clockwise using fuel tank lock ring wrench tool. Find the fuel tank part number on the front bottom of the tank.
Refer to SPECIFICATIONS for torques.
5. Remove fuel tank from bench to vehicle and support tank while connecting the fuel lines, vent line, and electrical connectors to appropriate places.
6. Install tank in vehicle and tighten straps.
7. Lower vehicle.
8. Install filler tube and attaching screws.
9. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
10. Turn ignition key to RUN position for 3 seconds repeatedly (5 to 10 times) until pressure gauge shows at least 240 kPa (30 psi). Check for leaks at fittings.
11. Remove pressure gauge, start engine, and recheck for leaks.