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 a hoist, do not raise.
2. Depressurize fuel system.
3. Remove fuel from fuel tank by pumping out through fuel tank filler pipe.
4. Raise vehicle on hoist.
5. Disconnect and remove fuel tank filler pipe.
6. Support fuel tank and remove fuel tank support straps. Lower fuel tank partially and remove fuel lines, electrical connectors, and vent lines from tank. Remove fuel tank to a bench.
7. Remove any dirt that has accumulated around fuel pump retaining flange so that it will not enter the the fuel tank during removal and installation.
8. Turn fuel pump locking retainer ring counterclockwise and remove fuel pump locking ring.
9. Remove fuel tank sending unit and pump.
10. Remove fuel pump mounting gasket and discard.

Fuel Pump/Sending Unit:

INSTALLATION

1. Clean fuel pump mounting flange and fuel tank mounting surface and fuel pump mounting gasket groove.
2. Put a light coating of premium long-life grease on a new fuel pump mounting gasket to hold it in place during assembly and install it in the groove.
3. Install fuel tank sending unit and pump carefully to ensure that nylon filter is not damaged.
4. Hold assembly in place and install fuel pump locking retainer ring finger tight. Ensure that all locking tabs are under tank lock ring tabs.
5. Secure unit with fuel pump locking retainer ring by rotating fuel pump locking retainer ring clockwise until ring stops against stop.
6. Move fuel tank from bench to vehicle. Support fuel tank while connecting fuel lines, vent line and electrical connectors to appropriate places.
7. Install fuel tank in vehicle and secure with retaining fuel tank support straps.
8. Lower vehicle.
9. Install fuel tank filler pipe and retaining screws.
10. Install a minimum of 10 gal. of fuel and check for leaks.
11. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until EFI and CFI Fuel Pressure Gauge T80L-9974-B shows at least 207 kPa (30 psi). Check for leaks at fittings.
12. Remove EFI and CFI Fuel Pressure Gauge T80L-9974-B, start engine, and recheck for leaks.