Fuel Pump: Service and Repair

FUEL PUMP







Exploded View

Special Tool(s):

Special 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.
- Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when working on or near any fuel-related components. Highly flammable mixtures are present and may be ignited. Failure to follow these instructions can result in 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. Remove the fuel tank.
2. Disconnect the fuel pump module electrical connector.
3. Disconnect the 2 fuel tube quick connect couplings from the pump module.







4. Using the special tool, remove the fuel pump module lock ring.

5. CAUTION:
- The fuel pump module must be handled carefully to avoid damage to the float arm and filter.
- Some fuel will remain in the fuel pump module after draining the fuel tank. Carefully drain the fuel pump module into a suitable container.

Remove the fuel pump module.

6. NOTE: Be careful that no foreign material falls into the tank.

Remove and discard the fuel pump module O-ring gasket and make sure the mounting area is clean and free of foreign material.

Installation

1. CAUTION:
- Inspect the surfaces of the fuel pump module flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or fuel tank. Install a new fuel pump module or fuel tank if the O-ring seal contact area is bent, scratched or corroded.
- Make sure to install a new fuel pump module O-ring seal and lock ring.

NOTE: To install, apply clean engine oil to the fuel pump module O-ring.

Install the fuel pump module.







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

When installing the fuel pump module, make sure to align the locator arrows on the fuel tank mounting flange and the fuel pump module.







3. Using the special tool, install the fuel pump module lock ring.
- Tighten the lock ring until fully seated against the lock stop tabs.

4. Connect the fuel pump module electrical connector.
5. Connect the fuel tube quick connect couplings.
6. Install the fuel tank.