Fuel Pump: Service and Repair

Fuel Sender Wrench:

SPECIAL SERVICE TOOL(S)

REMOVAL

WARNING:
^ DO NOT SMOKE OR 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.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.

1. Drain the fuel tank.
2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and Repair.







3. Remove the bolts and the nuts and position the exhaust heat shield on the exhaust system.







4. Loosen the right support strap approximately 1 inch.







5. loosen the left support strap approximately 1 inch.
6. Lower the hoist.







7. Disconnect the module fuel line connectors.
1 Press the release tabs on the module fitting.
2 Turn the fuel line slightly.
3 Pull straight up to remove the fuel line connector.

NOTE: Make sure the fuel line connector is fully seated prior to compressing the release tabs.







8. Disconnect the electrical connector.







9. Install the special tool and loosen the lockring retainer nut.
10. Continue removing the lockring retainer nut by hand.







11. Remove the fuel delivery module.

CAUTION: The fuel module must be handled carefully to avoid damage to the float arm and the filter during removal.


INSTALLATION
1. To install, reverse the removal procedure.

NOTE: New module assembly flange gaskets must be used. Gently position the module seal by hand and make sure it remains in position during installation. Make sure the fuel line tube connectors are fully seated into the outlet connector fittings.