Fuel Pump: Service and Repair

Fuel Line Disconnect Tool:

SPECIAL TOOL(S)

REMOVAL

WARNING:
^ WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE.
^ THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME.

1. Relieve the fuel pressure.
2. Disconnect the battery ground cable; refer to Battery.
3. Raise and support the vehicle; refer to Maintenance/Service and Repair.







4. Disconnect the fuel tank filler pipe hose from the fuel tank.
5. Drain the fuel from the fuel tank.







6. Disconnect the fuel tank vent tube from fuel tank filler pipe.







7. Disconnect the fuel pump electrical connector.







8. If equipped, remove fuel tank skid plate.
1 Remove the five fuel tank skid plate bolts.
2 Lower the fuel tank skid plate.







9. Position a suitable jack under the fuel tank.







10. Remove the front fuel tank support strap.
1 Remove the two bolts.
2 Remove the front fuel tank support strap.







11. Remove the rear fuel tank support strap.
1 Remove the three bolts.
2 Remove the rear fuel tank support strap.







12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses.







13. Remove the two safety clips from the fuel lines.







14. Disconnect the fuel lines from the fuel pump.
1 Install and push the (A) fuel line disconnect tool into the (B) female fitting.
2 Separate the male and female fitting.







15. Remove the fuel tank.







16. Remove the fuel pump.
1 Remove the fuel pump locking retaining ring.
2 Remove the fuel pump and discard the O-ring.

INSTALLATION







1. Install the fuel pump.
1 Install a new O-ring and fuel pump.
2 Install the fuel pump locking retainer ring.







2. With a suitable jack, position the fuel tank.







3. Connect the fuel lines.







4. Connect the safety clips.







5. Connect the EVAP emissions hoses.
6. Raise the fuel tank into position.







7. Install the rear fuel tank support strap.







8. Install the front fuel tank support strap.
1 Position the fuel tank support strap.
2 Install the bolts.







9. If equipped, install the fuel tank skid plate.
1 Position the fuel tank skid plate.
2 Install the bolts.







10. Connect the fuel pump electrical connector.







11. Connect the fuel tank-to-filler pipe vent tube.







12. Connect the fuel tank filler pipe hose.
13. Lower the vehicle.
14. Fill the fuel tank.
15. Turn on the air suspension system.
16. Connect the battery ground cable.