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.

Removal

1. Place vehicle on hoist, do not raise.
2. Depressurize fuel system with EFI and CFI fuel pressure gauge or equivalent. Connect pressure gauge on Schrader valve located on engine fuel rail. Open the valve and drain.
3. Remove fuel from fuel tank by pumping out through filler. Use care to prevent combustion from fuel spillage.
4. Raise vehicle on hoist.
5. Disconnect supply line and return line fittings and vent line at the RH and LH side rear axle frame kick-ups.
6. Disconnect fuel sender electrical connector forward of tank.
7. Remove filler neck ring clamp screw.
8. Remove fuel tank support straps and remove fuel tank and move tank to bench.
9. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the tank during removal and installation.
10. Disconnect the supply line and return line fittings and the electrical connector.
11. Turn the fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, and remove locking ring.
12. Remove fuel pump and bracket assembly.
13. Remove seal ring and discard.

Installation

1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.
2. Apply a light coating of Long-Life Lubricant Cl AZ-i 9590-BA (ESA-M1C75-B) or equivalent on a new seal ring to hold it in place during assembly and install in fuel ring groove.
3. Install fuel pump and bracket assembly carefully to ensure that filter is not damaged. Ensure locating keys are in keyways and seal ring remains in groove.
4. Hold pump assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.
5. Secure the fuel sending unit and pump assembly by rotating the locking ring clockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, until ring stops against stop tabs.
6. Move tank to vehicle. Raise tank partially and install vent line and fuel tubes.
7. Install electrical connector.
8. Install fuel line fittings.
9. Install tank in vehicle, and tighten straps.
10. Connect fuel sender electrical connector.
11. Lower vehicle.
12. Install filler tube and attaching screws.
13. Connect vent line.
14. Install fittings on RH and LH side of vehicle.
15. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
16. With Fuel Pressure Gauge T8OL-9974-B or equivalent on the fuel charging assembly Schrader valve. Turn ignition switch from OFF to ON position for three seconds. Repeat this OFF to ON switching (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi).
17. Remove pressure gauge, start engine, and check for leaks.