Fuel Pump: Service and Repair

WARNING: The fuel system is under constant pressure, even when the engine is OFF. Always release fuel pressure before servicing any fuel system component.

NOTE: The fuel pump is not serviceable, if the pump is defective replace the whole fuel pump module.

Pressure Relief/Rollover Valve:

REMOVAL
1. Release fuel pressure.
2. Drain and remove fuel tank.
3. Note the direction of fuel nipples and electrical connector for assembly.
4. While holding the fuel pump module down, remove the locknut, (locknut is threaded onto tank). Use a brass drift to loosen the fuel pump locknut, if necessary. After the locknut has been removed release the fuel pump module and it will spring up from the fuel tank.
5. Remove the fuel pump module from the fuel tank, being careful not to bend the sending unit float arm.

Fuel Gauge Sending Unit And In-Tank Filter:

FUEL GAUGE SENDING UNIT REMOVAL
1. Remove sending unit attaching screws from mounting bracket located on the side of the fuel pump reservoir.
2. Mark wires for installation, disconnect electrical connections from sending unit, and remove sending unit.

FUEL GAUGE SENDING UNIT INSTALLATION
1. Connect the electrical connections to the sending unit.
2. Install sending unit onto the fuel reservoir, and tighten the mounting screws.

IN-TANK FUEL STRAINER REMOVAL
1. Pry back the fuel strainer mounting tabs and pull the strainer off module.

Fuel Gauge Sending Unit And In-Tank Filter:

IN-TANK FUEL STRAINER INSTALLATION
1. Snap the fuel filter onto the mounting tabs of the fuel reservoir.

INSTALLATION

NOTE: Locknut and gasket must be replaced, whenever the fuel pump module is serviced.

1. Wipe seal area of tank clean, and install a new seal on pump.
2. Install new locknut over top of fuel pump module.
3. Push fuel pump module into the tank, being careful not to bend the sending unit float arm, and hold with one hand while tightening the locknut with the other hand.
4. Install fuel tank assembly.
5. Using scan tool, place ignition switch in "RUN" position and use Actuate Output Test "Auto Shutdown (ASD) Relay", to activate fuel pump and pressurize system.
6. Check for leaks.