Fuel Pump: Service and Repair

REMOVAL:

1. Place the vehicle on a hoist, do not raise.
2. Depressurize the fuel system by cranking the engine for a minimum of 15 seconds with the electrical connector at the inertia switch disconnected.
3. Remove the fuel from the fuel tank by pumping it out through the filler.
4. Raise the vehicle on the hoist.
5. Disconnect and remove the fuel filler tube. 6. Support the fuel tank and remove the fuel tank support straps. Partially lower the tank and remove the fuel lines, electrical connectors, and vent lines from the tank. Move the tank to a work bench.
7. Remove any dirt that has accumulated around the fuel pump retaining flange.
8. Turn the fuel pump retaining ring counterclockwise using Fuel Tank Sender Wrench D84P-9257-A or equivalent, and remove the lock ring.
9. Remove the fuel pump and bracket assembly.
10. Remove the seal ring and discard.

INSTALLATION:

1. Clean the fuel pump mounting flange, fuel tank mounting surface, and the seal ring groove.
2. Put a coating of Long Life Lubricant C1AZ-19590-BA (ESA-M1C75-C) or equivalent on a new seal ring to hold it in place during assembly and install it in the fuel ring groove.
3. Install the fuel pump sender assembly with caution to ensure that the nylon filter is not damaged. Make sure the locating keys are in the key ways and the seal ring remains in place.
4. Hold the assembly in place and tighten the locking ring finger-tight. Make sure the locking tabs are under the tank lock ring tabs.
5. Tighten the locking ring by rotating clockwise until the ring stops are against the lock ring stops on the tank.
6. Move the fuel tank from the work bench to the vehicle and support the tank while connecting the fuel lines, vent line, and electrical connectors.
7. Install the tank in the vehicle and secure in place using the retaining straps.
8. Install the filler tube and retaining screws.
9. Fill the fuel tank with a minimum of 38 liters (10 gallons) of fuel and check the tank for leaks.
10. START the engine and check for proper fuel pressure and recheck for fuel leaks.