Fuel Pump: Service and Repair

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. Clean the area around the fuel delivery module mounting flange.






3. Remove the module assembly flange bolts.






4. Pull the fuel delivery module assembly flange up and out of the fuel tank until the locking tabs on the module are accessible. Reach through the opening and squeeze the locking tabs together and remove the module from the fuel tank by lifting up and out.

CAUTION: The fuel delivery module must be handled carefully to prevent damage to the float arm, filter, convolute tubing and wiring.

INSTALLATION

NOTE: If the old fuel delivery module assembly is being reinstalled, check the condition of the fuel pump assembly flange seal and install a new flange seal if necessary.






1. Clean the fuel delivery module mounting flange and the fuel tank mounting surface.






2. Install the fuel delivery module by pushing down on the module until the module tabs click and engage the retainer.

CAUTION: The fuel delivery module must be handled carefully to prevent damage to the float arm and filter.

NOTE: Align the fuel delivery module with the fuel tank retainer.

3. Install the fuel delivery module assembly flange on the fuel tank.

NOTE: Align the fuel outlet tube to point toward the front of the vehicle.






4. Finger tighten the bolts, then tighten using the sequence shown.
5. Install the fuel tank.