Fuel Pump: Service and Repair

CAUTION: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced. The fuel system on these vehicles is depressurized by disconnecting the inertia switch and cranking the vehicle for a minimum of 15 seconds.

REMOVAL

1. Depressurize fuel system, refer to Service and Repair / Fuel Pressure Relief Procedure.
Fuel Pressure Release

2. Remove fuel from fuel tank by pumping out through filler into a suitable storage tank. Use care to prevent combustion from fuel spillage.

3. Remove fuel tank to bench.

4. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during procedures.

5. Unscrew and remove the six M6 fasteners.

6. Remove the fuel pump and sender assembly from the fuel tank.

7. Remove seal gasket and discard.

8. If necessary, disconnect spade connector and remove two screws and fuel sending unit.

INSTALLATION

1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.

2. Put a light coating of grease on a new seal ring to hold it in place during assembly and install it in the fuel ring groove.

3. Install fuel pump and sender assembly carefully to ensure that the filter is not damaged. Be sure that the locating keys are in keyways and the seal ring remains in place.

4. Hold the fuel sender and sealing gasket in place, install and the six M6 fasteners. Torque fasteners to 9.0-12 Nm (7-9 lb ft).

5. Install the fuel tank in vehicle.