Fuel Pump: Service and Repair

Fuel 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.

REMOVAL

WARNING: Use care to prevent combustion from fuel spillage.

1. Place vehicle on hoist, do not raise.
2. Depressurize fuel system.
3. Remove fuel from fuel tank by pumping out through filler neck using suction hose.
5. Raise vehicle on hoist.
5. Disconnect and remove fuel filler tube.
6. Support fuel tank and remove fuel tank support straps. Lower fuel tank partially and remove fuel lines, electrical connectors and vent lines from tank. Remove fuel tank
7. Remove any dirt that has accumulated around fuel pump attaching flange so that it will not enter fuel tank during removal and installation.
8. Turn fuel pump locking ring counterclockwise and remove locking ring.
9. Remove fuel pump and bracket assembly.
10. Remove seal gasket and discard.

INSTALLATION

1. Clean fuel pump mounting flange and fuel tank mounting surface and seal ring groove.
2. Put a light coat of oil on a new seal ring to hold it in place during assembly and install it in fuel ring groove.
3. Install fuel pump and sender assembly carefully to ensure that filter is not damaged. Ensure that locating keys are in keyways and seal ring remains in place.
5. Hold assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.
5. Secure unit with locking ring by rotating ring clockwise using a fuel tank sender wrench until ring stops against stops.
6. Position and support fuel tank to facilitate connecting fuel lines, vent line, and electrical connectors to appropriate places.
7. Install tank in vehicle and tighten straps.
8. Lower vehicle.
9. Install filler tube and attaching screws.
10. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
11. Turn ignition switch to ON position for three seconds repeatedly (5 to 10 times) until pressure gauge shows at least 270 kPa (30 psi). Check for leaks at fittings.
12. Remove pressure gauge, start engine, and recheck for leaks.