Fuel Pump: Service and Repair

SPECIAL SERVICE TOOL(S) REQUIRED

Description
- Fuel Pressure Gauge

Tool Number
- 310-012 (T80L-9974-B)






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. Remove the fuel tank.
2. Disconnect the pressure transducer connector on the RH top side of fuel tank.
3. Remove any dirt that has accumulated around the fuel pump module so it will not enter the fuel tank during removal and installation.
4. Remove six bolts from around perimeter of fuel pump module.
5. Remove fuel pump module.

INSTALLATION

1. Clean fuel pump module mounting flange and the fuel tank mounting surface.
2. Install fuel pump module carefully to prevent filter damage.
3. Install six bolts around fuel pump module and pump perimeter and tighten to 8-10 Nm (71-88 lb in).
4. Connect the pressure transducer connector.
5. Install the fuel tank.
6. Install a minimum of 38L (10 gal) of fuel and check for leaks.
7. With Fuel Pressure Gauge 310-012 (T80L-9974-B) connected to the fuel pressure relief valve on the fuel supply manifold, turn ignition switch from OFF to RUN (engine off) for three seconds. Repeat this OFF to RUN switching (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi).
8. Remove pressure gauge, start engine and check for leaks.