Fuel Pump: Service and Repair

Fuel Pump Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Remove the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
3. Disconnect the following components:

* The fuel feed
* The return pipe
* The EVAP pipe quick-connect fittings at fuel sender assembly
Refer to Metal Collar Quick Connect Fitting Service Service and Repair or to Plastic Collar Quick Connect Fitting Service Service and Repair.




4. Remove the following components:

* The fuel sender assembly electrical connector (7)
* The 6 nuts and washers (1) retaining the fuel sender assembly lock ring (8).
* The lock ring
* The Fuel Tank
Support and slide out the tank until the fuel sender assembly clears the cab.
* The fuel pump sender assembly
* The seal from the fuel tank

5. Disconnect the fuel pump electrical connector.
6. Remove the fuel pump strainer from the bottom of the fuel pump.
7. Rotate the strainer in one direction and pull the strainer off the pump. Discard the strainer after inspection.

Important: Do not damage the rubber insulator.


8. Remove the fuel pump (4) from the sender assembly (2). Pull the fuel pump up into the attaching hose while pulling outward from the bottom support.
9. Inspect the fuel pump attaching hose for signs of deterioration.
10. Inspect the rubber sound insulation at the bottom of the pump.

Installation Procedure





Important: Care should be taken not to fold over or twist the strainer (3), when installing the sender assembly as this will restrict fuel flow.


1. Install the fuel pump assembly (4) into the attaching hose.
2. Install the fuel pump strainer.
3. Connect the fuel pump electrical connector.
4. Install the new seal, sender assembly (2), and lock ring (8) in the fuel tank.
Make sure the lock ring alignment holes fit over the tabs on the tank.

Notice: Refer to Fastener Notice in Cautions and Notices.

5. Install the washers and nuts (1) retaining the fuel sender assembly lock ring.

Tighten the lock ring nuts to 11.5 Nm (100.90 lb in).

6. Install the fuel tank. Slide the tank into the original position.
7. Install the following components:

* The fuel feed
* The return
* The EVAP pipe quick-connect fittings at fuel sender assembly
Refer to Metal Collar Quick Connect Fitting Service Service and Repair and Plastic Collar Quick Connect Fitting Service Service and Repair.

8. Install the fuel sender assembly electrical connector (7).
9. Install the negative battery cable.
10. Inspect for fuel leaks using the following procedure:

1. Turn the ignition switch to ON position for 2 seconds.
2. Turn the ignition switch to OFF for 10 seconds.
3. Turn the ignition switch to ON position.
4. Inspect for fuel leaks.