Fuel Pump: Service and Repair

REMOVAL

1. Loosen threaded fuel line connections and retighten snugly. Do not remove lines at this time.
2. Loosen mounting bolts one to two turns. Rotate the engine, by nudging the starter, until the fuel pump cam lobe is near its low position. The tension on the fuel pump will be greatly reduced at the low cam position.

NOTE: Outlet line is pressureized. Disconnect the fuel pump inlet, outlet and fuel vapor return line if so equipped. Use care to prevent combustion of spilled fuel.

3. Remove the fuel pump attaching bolts and remove the pump and gasket.


4. Measure the fuel pump pushrod length. It should be 98.6-99mm (3.88-3.90 inch). Replace if worn or out of specification. Reinstall pump and repeat pressure test.



INSTALLATION

1. Remove all fuel pump gasket material from the engine and fuel pump (if reinstalling the original pump).
2. Install the attaching bolts into the fuel pump and install a new gasket on the bolts. Position the fuel pump to the mounting pad. Turn the attaching bolts alternately and evenly and tighten to specification.
3. Install fuel outlet line. tighten connection to 20-24 Nm (15-18 lb ft).
4. Install inlet line and fuel vapor return line (if so equipped). Install hose clamps. (Replace any cracked, hardened or frayed rubber hoses.)
5. Start engine and check for leaks. (Observe for at lease two minutes.) Stop engine and check all fuel pump connections for leaks by running a finger under the connections. Check for oil leaks at the fuel pump mounting pad.