Fuel Pump: Service and Repair

Fuel delivery unit, removing and installing


WARNING!
Fire hazard! Do NOT have anything in the area that can ignite gasoline!


Special tools and equipment







- 3217 Ring nut wrench

Removing
- Note safety precautions before starting work


CAUTION!
Obtain radio anti-theft code from customer BEFORE disconnecting battery Ground strap!


- With ignition switched OFF, disconnect battery Ground strap.
- Fold bench seat forward.
- Remove cover under bench seat.
- Remove metal cover for fuel delivery unit (three screws).


WARNING!
Fuel supply lines are underpressure! Before removing from hose connection, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.







- Disconnect 4-pin harness connector and supply and return lines -arrows- from flange.


NOTE: Press down on fuel line connectors to release.







- Remove union nut using 3217 wrench.
- Pull fuel delivery unit and seal out of fuel tank opening.


NOTE: If the delivery unit being replaced; properly drain old delivery unit before disposal.


Installing
Installation is carried out in the reverse order of the removal procedure.


NOTE:
- Do not bend the fuel sensor when installing.
- Insert seal for fuel delivery unit dry into opening of fuel tank.
- Moisten seal with fuel only when installing fuel delivery unit.
- Ensure that fuel hoses are securely seated.







- Note installed position of fuel delivery unit flange: Mark on flange must align with mark on fuel tank -arrows-.
- After installing fuel delivery unit, check that the supply, return and vent lines are still clipped to the fuel tank.
- Check DTC memory:
- Match Engine Control Module to Throttle Control Module:
- Check Readiness code:
- If DTCs are stored in the ECM or ECM receives low voltage when ignition is on, Readiness code must be reset:


Fig. 1 Fuel delivery unit flange, installed position







NOTE:
- Mark on sensor must align with mark on fuel tank -arrows-.
- Blue or blue marked return line -1- to connection with identification -R-.
- Black supply line -2- to connection with identification -V-.
- After installing fuel delivery unit flange, ensure that supply, return and breather lines are still clipped to the fuel tank.