Fuel Pump Module Replacement

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: It is not necessary to remove the fuel tank to service the fuel pump/sender unit.

Fuel Tank Locking Ring Removal And Hoses:

REMOVAL
1. Remove the fuel filler cap to relieve any fuel tank pressure.
2. Disconnect the negative battery cable.
3. Drain the fuel tank until the gauge read less than 1/4 full using a portable gasoline storage/siphon tank, or appropriate substitute. Raise and support the vehicle.
4. Disconnect the fuel vent, supply, and return hoses from their connections on the fuel pump/sender unit. Disconnect the fuel pump/sender electrical connections from the main harness.
5. Using a hammer, and BRASS PUNCH, remove the fuel pump/sender lock ring by tapping it in a counterclockwise direction. Remove the fuel pump lock ring, and the pump/sender assembly.
6. Remove and discard the fuel pump "O" ring seal, and the fuel pump sock style inlet filter.

Fuel Pump Assembly Throttle Body Injection:

DISASSEMBLY
1. Disconnect the fuel pump terminal wires.
2. Remove the fuel pump outlet hose and clamp, and discard the hose if it shows any signs of wear.
3. Remove the fuel pump top mounting bracket nut, and remove the pump.

ASSEMBLY
NOTE: Whenever the fuel pump is replaced, a new sock style fuel pump inlet filter must be installed.

1. Place fuel pump top mounting bracket over the top of the pump, and position the pump into the lower bracket. Slide the stud of the top bracket through the hole in the fuel pump side bracket. Install and tighten the fuel pump mounting nut.
2. Install a new fuel pump outlet hose, and secure the hose with a new clamp. Reconnect the wire terminals to the fuel pump motor.
3. Install a new sock style fuel pump inlet filter.

Fuel Pump Assembly Installed:

INSTALLATION
1. Install a new "O" ring on the pump/sender unit, and install the unit into the fuel tank. Be sure that the rubber stopper on the end of the fuel return tube is inserted into the cup in the fuel tank reservoir.
2. Using a hammer and brass punch, install the fuel pump/sender lock ring, and tap it into place in a clockwise direction. Tighten the lock ring until it locks against the stop on the fuel tank.
3. Reconnect the fuel supply, return, and vent hoses and tighten clamps securely. Connect the fuel pump/sender electrical connections into the main harness.
4. Refill the fuel tank, and install the fuel tank cap. Reconnect the negative battery cable,
5. Use the DRB II to select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures. Testing and Inspection

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test.