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.

1. Depressurize the fuel system as explained above then disconnect the fuel pump / sender electrical connector.
2. Remove the access cover over the fuel pump sender unit.
3. Remove any dirt that has accumulated around the fuel pump retaining flange so that it will not enter the fuel tank during removal and installation.
4. Remove the fuel pump assembly retaining screws.
5. Remove the fuel pump and bracket assembly.
6. Remove the seal gasket and discard.
7. If the sender unit is defective, remove it from the fuel pump assembly and replace it.
8. If the fuel pump is defective, remove the sender unit and install it on the new pump assembly.

Installation

1. Clean the fuel pump mounting flange, fuel tank mounting surface, and seal ring groove.
2. Apply a light coating of Long Life Lubricant Cl AZ- 19590-BA (ESA-M 1 C75-B) or equivalent on a new seal ring to hold it in place during assembly and install it in the fuel ring groove.
3. Install the fuel pump and sender assembly carefully to ensure that the filter is not damaged. Ensure that the locating keys are in keyways and the seal ring remains in place.
4. Install the fuel pump assembly retaining screws.
5. Replace the access cover.
6. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
7. Turn the ignition switch to the ON position for three seconds repeatedly (5 to 10 times) until the pressure gauge shows at least 270 kPa (30 psi). Check for leaks at the fittings.
8. Remove the pressure gauge, start the engine, and recheck for leaks.