Fuel Pump: Service and Repair

MECHANICAL

1. Loosen fuel supply attaching nuts at fuel pump outlet using suitable tool.
2. Loosen fuel pump attaching bolts approximately two turns, then manually rotate engine to position pump pushrod on low side of cam.
3. Remove rubber hose and clamp from fuel pump inlet, then disconnect fuel line from fuel pump inlet.
4. Disconnect fuel line from fuel pump outlet, then remove pump attaching bolts, fuel pump gasket and pushrod.
5. Reverse procedure to install.

ELECTRIC

Fuel supply lines will remain pressurized for long periods of time after engine shut-down. This pressure must be relieved before any service is attempted. A valve is provided on the fuel rail assembly for this purpose. To relieve system pressure, remove air cleaner assembly and connect pressure gauge tool No. T80L-9974-A or equivalent, onto fuel diagnostic valve on the fuel rail assembly. Gradually release fuel system pressure.
1. Disconnect battery ground cable.
2. Depressurize fuel system as described previously.
3. Raise and support vehicle.
4. Loosen fuel pump mounting bolt until fuel pump can be removed from vehicle.
5. Remove parking brake cable from pump clip.
6. Disconnect electrical connector and fuel pump outlet fitting.
7. Disconnect fuel pump inlet line from pump. Either drain fuel tank or raise end of fuel line above fuel level in tank to prevent fuel siphon action.
8. Remove pump from vehicle.
9. Reverse procedure to install. To pressurize fuel system, proceed as follows:
a. Install pressure tool gauge No. T80L-9974-A or equivalent onto fuel rail pressure fitting.
b. Turn ignition switch to ON position for 2 seconds and repeat turning ignition switch ON and OFF at 2 second intervals until gauge tool indicates approximately 35 psi.