Fuel Pump: Service and Repair

LOW-PRESSURE PUMP

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.

NOTE: The low-pressure pump is not serviced separately. It and the fuel sending unit are replaced as an assembly.

Removal

1. Remove the fuel tank. If necessary.






2. Remove the sending unit/fuel pump lock ring using Lock Ring Tool D84P-9275-A, or equivalent. Turn the lock ring counterclockwise to release from the tank.






3. Remove the lock ring, seal ring and sending unit/fuel pump from the fuel tank.

Installation

1. Clean the fuel tank seal ring groove.
2. Put a light coating of C1AZ-19590-B, or equivalent heavy-duty grease, on a new seal ring to prevent the lock ring from dragging on the seal during installation.






3. Position the new seal ring in the fuel tank groove.
4. Position the sending unit/fuel pump in the fuel tank.
5. Hold the assembly in position and install the lock ring fingertight. Make sure that all locking tabs are under the tank lock ring tabs.
6. Tighten the lock ring using Lock Ring Tool D84P-9275-A, or equivalent.
7. Install the fuel tank. If necessary.