Fuel Pump: Service and Repair

WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube.

REMOVAL

1. Depressurize fuel system.
2. Remove fuel from fuel tank by pumping out through filler pipe.
3. Disconnect supply line and return line fittings.
4. Disconnect fuel pump/sender electrical connector.
5. Remove any dirt that has accumulated around the fuel pump attaching flange.
6. Disconnect the supply line and return line fittings and the electrical connector.
7. Remove six bolts from around perimeter of fuel pump.
8. Remove fuel pump/sending unit assembly.
9. Remove seal ring and discard.

Fuel Pump/Sender Assembly:

INSTALLATION

1. Clean the fuel pump mounting flange, the fuel tank mounting surface and seal ring groove.
2. Apply a light coating lubricant on a new seal ring to hold it in place during assembly and install in fuel ring groove.
3. Install fuel pump/sending unit assembly, to ensure that filter is not damaged.
4. Hold pump assembly in place and install six bolts around pump perimeter and tighten to 8.0-10 Nm (71-89 lb in).
5. Secure fuel sending unit and pump assembly by rotating the locking ring clockwise, until the ring stops against the stop tabs.
6. Install electrical connector.
7. Install fuel line fittings.
8. Install a minimum of 10 gallons of fuel and check for leaks.
9. With a fuel pressure gauge on schrader valve, turn the ignition switch ON/OFF for three seconds. Repeat this ON/OFF switching (5 to 10 times) until the pressure gauge shows at least 35 psi.
10. Remove pressure gauge, start engine and check for leaks.