Fuel Pump: Service and Repair
REMOVALNote: The fuel tank and skid plate assembly must be removed from the vehicle to remove the fuel pump/sending unit assembly.
1. Disconnect the negative battery terminal.
2. Drain the fuel tank, using a gasoline storage/siphon tank or acceptible substitute.
Fuel Pump/Gauge Sender Unit Removal/Installation:
3. On vehicles with 20 gallon fuel tanks: Remove the 8 fuel pump/sending unit mounting bolts, and lift the unit out of the tank. Discard the mounting gasket.
Fuel Tank Locking Ring Removal And Hoses:
4. On vehicles with 15 gallon fuel tanks: Use a brass punch and hammer to remove the fuel pump/sending unit lock ring. Drive the lock ring counterclockwise and remove the assembly from the tank. Discard the "O" ring.
DISASSEMBLY
Fuel Pump Assembly Throttle Body Injection:
1. Remove and discard the fuel pump sock style inlet filter. Disconnect the fuel pump terminal wires.
2. Remove the fuel pump outlet hose and clamp, and discard the hose if it shows any signs of wear.
3. Remove the fuel pump top mounting bracket nut, and remove the pump.
ASSEMBLY
NOTE: Whenever the fuel pump is replaced, a new sock style fuel pump inlet filter must be installed.
1. Place fuel pump top mounting bracket over the top of the pump, and position the pump into the lower bracket. Slide the stud of the top bracket through the hole in the fuel pump side bracket. Install and tighten the fuel pump mounting nut.
2. Install a new fuel pump outlet hose, and secure the hose with a new clamp. Reconnect the wire terminals to the fuel pump motor.
3. Install a new fuel pump sock style filter.
INSTALLATION
NOTE: Whenever the fuel pump is replaced, a new sock style fuel pump inlet filter must be installed.
1. Install the fuel pump/sending unit into the fuel tank, with a new gasket or "O" ring.
^ On 20 gallon tanks: Install and torque the mounting bolts to 18 lb-in (2 Nm).
^ On 15 gallon tanks: Tap the lock ring clockwise with a brass punch and hammer until the ring locks against the stops on the fuel tank.
2. Install the fuel tank.
3. Refill the fuel tank, and install the fuel tank cap. Reconnect the negative battery cable, START the engine and check for leaks.