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. Place vehicle on hoist, do not raise.
2. Depressurize fuel system by installing EFI and CFI fuel pressure gauge T8OL-9974-B or equivalent to Schrader valve located on the engine fuel rail assembly. Open the valve and drain into suitable container.
3. Remove fuel from fuel tank through filler neck using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent.
4. Disconnect fuel supply and return lines in front of fuel tank.
5. Disconnect vent hose in front of fuel tank.
6. Remove filler neck ring clamp screw and remove fuel tank straps.






7. Lower tank slowly with transmission jack to access fuel pump electrical connector and disconnect.
8. Lower fuel tank and move to bench.
9. Disconnect fuel supply and return lines from fuel sender and pump assembly.
10. Remove any dirt that has accumulated around the fuel pump retaining flange so that it will not enter the tank during removal and installation.






11. Turn the fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, and remove locking ring.






12. Remove fuel pump and bracket assembly.
13. Remove seal gasket and discard.

Installation

1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.
2. Apply a light coating of Long Life Lubricant C1AZ-19590-BA (ESA-M1C75-B) or equivalent on a new seal ring to hold it in place during assembly and install in fuel ring groove.






3. Install fuel pump and bracket assembly carefully to ensure that filter is not damaged. Ensure locating keys are in keyways and seal ring remains in groove.
4. Hold pump assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.






5. Secure the fuel pump unit by rotating the locking ring clockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent until ring stops against stops.
6. Connect fuel supply and return lines onto fuel sender and pump assembly.






7. Position fuel tank under vehicle and raise partially. Install fuel pump electrical connectors.
8. Raise tank to mounting position and install fuel tank retaining straps. Position filler neck and install ring clamp.
9. Connect vent line.
10. Connect fuel supply and return lines.
11. Lower vehicle.
12. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
13. With Fuel Pressure Gauge T80L-9974-B or equivalent on the fuel charging assembly fuel diagnostic valve, turn ignition switch from OFF to ON position for three seconds. Repeat this OFF to ON switching (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.
14. Remove pressure gauge, start engine, and check for leaks.