Fuel Pump: Service and Repair

The OEM service manual does not provide fuel pump service and repair information. Refer to Fuel Sender Assembly.

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 34730-1A Fuel Pressure Gauge

REMOVAL PROCEDURE

CAUTION:
^ In order to Reduce the Risk of Personal Injury: Always allow for proper ventilation when working with fuel in enclosed areas
^ Refer to Safety Goggles and Fuel Caution in Service and Precautions.




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. Service and Repair
2. Drain fuel tank. Refer to Fuel Tank Draining Procedure. Procedures
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove fuel tank (4).
5. Remove the locking nut by turning the ring counterclockwise.

IMPORTANT: The modular fuel sender assembly may spring up from its position. When removing the modular assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. Tip the modular assembly slightly during removal to avoid damage to the float. Have a shop towel ready to absorb any leakage.

6. Remove modular fuel sender assembly (1) from the fuel tank.
7. Remove fuel sender seal (lip). Slide the fuel sender lip seal downward, past the reservoir and carefully over the float arm assembly
8. Discard the fuel sender lip seal.
9. Carefully discard the reservoir fuel into an approved container.

INSTALLATION PROCEDURE

IMPORTANT: Lip seal should be carefully positioned over the float arm assembly, moved up over the reservoir and half way up the guide posts.




1. Install new lip seal on modular fuel sender assembly. Always use a new lip seal when servicing modular fuel sender unit.
2. Lightly lubricate the inside diameter of the lip seal with clean engine oil.
3. Install modular fuel sender assembly (1) into the fuel tank. Seat the lip seal into tank opening.
4. Align arrow on top of the fuel sender cover to arrow on the fuel tank.

IMPORTANT: Be sure that the lip seal provides a snug seal between the modular unit and the fuel tank.

5. Slowly apply pressure to the top of the spring loaded sender until the lip seal is flush between the fuel tank and the fuel sender cover.
6. Install the locking ring by turning clockwise.
7. Install the fuel tank.




8. Lower the vehicle.
9. Add fuel to the fuel tank.
10. Reinstall the fuel tank filler pipe cap.

CAUTION: Refer to Battery Disconnect Caution in Service and Precautions.

11. Connect the negative battery cable.
12. Inspect for fuel leaks.
12.1. Turn ON the ignition for 2 seconds.
12.2. Turn OFF the ignition for 10 seconds.
12.3. Turn ON the ignition.
12.4. Check for fuel leaks.




13. Install the fuel injector sight shield (1) to the engine.

NOTE: Refer to Fastener Notice in Service and Precautions.

14. Install the fuel injector sight shield nuts (2).

Tighten
Tighten the nuts 3 N.m (27 lb in).