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.

Low Pressure In-Tank Pump Assembly Removal

The low pressure fuel pump is located in the top of the fuel tank and requires removal of the fuel tank for servicing. The low pressure pump is removed in the same manner as the fuel sender, i.e. remove hoses from fittings, remove locking ring and remove assembly from tank.

Installation

1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.
2. Apply a light coating of C1AZ-19590-B or equivalent heavy duty grease on a new seal ring to hold it in place during assembly and install in fuel ring groove.
3. Carefully install fuel pump and bracket assembly to ensure that filter is not damaged. Be sure that locating keys are in keyways and seal ring remains in groove.
4. Hold pump assembly in place and install locking ring fingertight, being sure that all locking tabs are under tank lock ring tabs.
5. Secure the fuel pump unit with the locking ring by rotating clockwise with tool until ring stops against stops.
6. Install electrical connector.
7. Install fuel line fittings.
8. Install tank in vehicle, and tighten straps.
9. Lower vehicle.
10. Install filler tube and attaching screws.
11. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
12. Install Pressure Gauge Tool T8OL-9974-A or equivalent on the fuel charging assembly fuel diagnostic valve and turn ignition key to On position for 3 seconds. Turn ignition key Off and On for 3 seconds repeatedly (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.
13. Remove pressure gauge, start engine, and recheck for leaks.