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. Place vehicle on hoist, do not raise.
2. Perform fuel system release procedure.
3. Drain fuel from fuel tank.
4. Raise vehicle on hoist. Use proper vehicle lifting procedures.
5. Remove fuel tank and move to bench.
6. Remove any dirt that has accumulated around the fuel pump module so that it will not enter the fuel tank during removal and installation.
7. Remove six bolts from around perimeter of fuel pump module.
8. Remove fuel pump module from fuel tank.
9. Remove O-ring seal and discard.






INSTALLATION

1. Clean fuel pump module retaining flange, fuel tank mounting surface and seal ring groove.
2. Install new O-ring seal.
3. Install the fuel pump module carefully into the fuel tank to make sure that the filter, hoses and float rod are not damaged or binding.
4. Install six bolts around fuel pump module perimeter and tighten to 8-10 Nm (71-88 lb in).
5. Move fuel tank from bench to vehicle.
6. Install fuel tank.
7. Lower vehicle.
8. Install a minimum of 38 L (10 gal) of fuel and check for leaks.
9. With Fuel Pressure Gauge T80L-9974-B connected to the fuel pressure relief valve on the fuel supply manifold, turn ignition switch from OFF to RUN (engine off) for three seconds. Repeat this OFF to RUN switching (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi).
10. Remove pressure gauge, start engine and check for leaks.