Fuel Pump: Service and Repair

Tools Required:
Fuel Tank Sender Wrench D84P-9275-A
Rotunda Fuel Storage Tanker 034-00002
Rotunda Adapter Hose 034-00012

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.
3. Drain fuel from fuel tank through fuel tank filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent.
4. Raise vehicle on hoist.
5. Disconnect and remove fuel tank filler pipe.
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 to bench.
7. Remove any dirt that has accumulated around fuel pump retaining flange so that it will not enter fuel tank during removal and installation.
8. Turn fuel pump locking retainer ring (9C385) counterclockwise using Fuel Tank Sender Wrench D84P-92 75-A or an equivalent and remove fuel pump locking retainer ring.
9. Remove fuel tank sending unit and pump.
10. Remove seal gasket and discard.

Installation

1. Clean the fuel tank sending unit and pump mounting flange, fuel tank mounting surface and seal ring groove.
2. Apply a light coating of Premium Long-Life Grease XG- 1-C (ESA-M 1 C75-B) or equivalent on a new seal ring to hold it in place during assembly and install it in fuel ring groove.
3. Install fuel tank sending unit and pump carefully to ensure that filter is not damaged. Ensure that locating keys are in keyways and seal ring remains in place.
4. Hold assembly in place and install fuel pump locking retainer ring finger-tight. Ensure that all locking tabs are under fuel tank lock ring tabs.
5. Secure unit with fuel pump locking retainer ring by rotating fuel pump locking retainer ring clockwise using Fuel Tank Sender Wrench D84P-9275-A or an equivalent until fuel pump locking retainer ring stops against stops.
6. Remove fuel tank from bench to vehicle and support fuel tank while connecting fuel lines, vent line, and electrical connectors to appropriate places.
7. Install fuel tank in vehicle and secure with fuel tank support straps.
8. Lower vehicle.
9. Install fuel tank filler pipe and retaining screws.
10. Install a minimum of 381(10 gal) 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.