Fuel Pump: Service and Repair

Figure 1 - Modular Fuel Sender Disassembly To Replace Fuel Pump:

Figure 2 - Fuel Pulse Dampener Removal:

Figure 3 - Fuel Pump Removal:

Fuel Pump Module Exploded View:

REMOVE OR DISCONNECT

1. Relieve fuel system pressure (refer to FUEL PRESSURE RELIEF).
2. Drain fuel tank (see FUEL TANK DRAINING).
3. Fuel tank (see FUEL TANK REPLACEMENT).
4. Modular fuel sender assembly (refer to MODULAR FUEL SENDER ASSEMBLY Service and Repair).
5. Under cover wire harness from the cover.
- Connector Position Assurance (CPA) from under the cover. Apply pressure (with a small screwdriver) downward against the (red) CPA to remove it from the wire harness (save the CPA).
- Depress the black connector tabs to remove the electric connector from the cover.
6. Wire connector to fuel pump by depressing with a screwdriver.
7. Drain pipe from the retainer and bumper pad
8. Reservoir from retainer at locking tabs.
CAUTION: Follow the exact order described when disassembling the modular unit to service the fuel pump.
NOTE: Damage to the locking retainer tabs, the reservoir, or the guide rod, will result in unit replacement.
9. Locate the curved side of the modular unit's reservoir as shown, in Figure. Begin at locking Tab 1, squeeze the reservoir to release the first locking tab as shown in Figure 1, step 1.
10. Moving clockwise to locking Tab 2 location, apply gentle pressure to the guide rod to release the second locking tab as shown in figure 1, step 2.
11. At locking Tab 3 gently twist and squeeze to release the reservoir from the retainer as shown in Figure 1, step 3.
12. Cover and the retainer from the reservoir.
- Be careful not to damage the crossover tube. The unit will still be attached by the convoluted fuel pipe and the crossover tube.
13. External strainer.
- Use a screwdriver to carefully pry the strainer ferrule off the reservoir. Excessive force may dislodge the jet pump. Note strainer position for later reinstallation. Discard the strainer.
14. Rubber pad (bumper) and discard.
15. Fuel pump as shown in figure 3.
- The fuel pump and fuel pump sleeve assembly are attached to the retainer when pulled from the reservoir.
- Depress the flex member on the pump sleeve and rotate the sleeve counterclockwise to remove the fuel pump from the retainer. Note orientation of pump to retainer.
16. Fuel pulse dampener as shown in Figure 2. Slide lower connector assembly out of the retainer to remove fuel pulse dampener from the lower connector. Note orientation of seal (the modular unit is now held together by the crossover tube only). Discard fuel pulse dampener.


INSTALL OR CONNECT

1. Fuel pulse dampener. Always use a new fuel pulse dampener when installing a new fuel pump.
2. Slide lower connector into retainer.
3. Fuel pump.
- Push pump outlet tube into fuel pulse dampener and rotate flex member back to original position.
- Line up pump with outlet into retainer opening. All three sleeve tabs should protrude through the retainer before rotating.
- Rotate clockwise in place (will click). Be sure fit is snug before rotating.
- Place fuel pump back into reservoir. Crossover tube must be placed in proper slot.
4. New rubber pad (bumper) as noted in disassembly.
5. Drain tube. Insert drain tube into proper retainer and bumper pad slots.
6. New external strainer. Always use new external fuel sender assembly strainer when servicing the unit.
NOTE: If excessive force is used, the jet pump could be dislodged.
7. Fuel pump wire connector.
8. Undercover wire harness connector and CPA.
9. Modular fuel sender unit (See MODULAR FUEL SENDER ASSEMBLY - Service and Repair).