Fuel Pump: Service and Repair

WARNING: Before disconnecting any fuel line, release fuel pressure with the following procedure. When replacing fuel system components, keep sparks, cigarettes and open flames away from fuel. Use a rag as protection from spray when disconnecting hoses. Plug hoses while they are disconnected.

RELIEVING FUEL SYSTEM PRESSURE

Relieving Fuel System Pressure:

1. Start engine.
2. Disconnect fuel pump relay (circuit opening relay) connector.
3. After engine stalls, turn ignition "OFF."
4. Reconnect fuel pump relay connector.

FUEL PUMP REPLACEMENT

Fuel Pump Replacement:

1. Remove rear package deck trim and service hole cover.
2. Disconnect fuel hoses and pump electrical connector.
3. Remove fuel pump cover screws.

Fuel Pump/Sender Unit Assembly:

4. Lift pump and fuel tank gauge sender unit assembly from tank.
5. Carefully pry filter screen from pump inlet and remove pump from assembly.

Fuel Pump Seal Installation:

6. Install in reverse order of removal. Use a new O-ring set (O-ring, cap, and spacer).
7. Apply a light coating of oil or fuel to O-ring set prior to installation.
8. To confirm O-ring sealing after assembling pump to fuel tank gauge sender unit, blow into fuel outlet pipe and verify that no air flows. If air flows, the pump check ball may be stuck or the O-ring is not sealing. Gently shake pump and recheck.
9. After installing pump, pull it down so that it is firmly seated against bottom bracket.
10. Reinstall filter screen. Install a new screen if it is damaged in any way.
11 Reinstall assembly in tank and attach hoses and electrical connector.
12. Replace rear package deck trim and service hole cover.

FUEL SYSTEM PRIMING

Fuel System Priming:

NOTE: After releasing fuel system pressure for any reason, the system must be primed to avoid excess cranking when first starting the engine.

1. Connect a jumper wire across diagnosis connector terminals "F/P" and "GND."
2. Turn ignition "ON" for approximately 10 seconds and check for fuel leaks.
3. Turn ignition "OFF" and remove jumper wire.
4. Repair any leaks that may have been detected and recheck before starting engine.