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.
3. Drain fuel from fuel tank.
4. Raise vehicle on hoist.

NOTE: The plastic fuel tube connections are on top of the fuel tank and are inaccessible. The fuel tank must be lowered to gain access to the connections.

5. Disconnect fuel hoses and tubes. Disconnect one end of the fuel tank vent tube at the rear over the driveshaft. Disconnect fuel tank filler pipe.
6. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps. Take care not to deform the fuel tank. or fuel tank support straps to avoid affecting fuel tank capacity and/or fuel pick-up.
7. Lower the fuel tank and disconnect the fuel lines and electrical connector from the fuel gauge sender, if required.
8. Remove dirt that has accumulated around the fuel tank sending unit and pump retaining flange so that it will not enter the fuel tank during removal and installation.
9. Turn the fuel pump locking retainer ring counterclockwise using Fuel Tank Sender Wrench D90P-9275-A or equivalent, and remove fuel pump locking retainer ring.
10. Remove fuel tank sending unit and pump assembly.
11. Remove fuel pump mounting gasket and discard.

INSTALLATION

1. Clean the fuel tank sending unit and pump mounting flange, fuel tank mounting surface and seal ring groove.
2. Apply a light coating of Premium Long-Life Grease XG-1-C (ESA-M 1C75-B) or equivalent on a new fuel pump mounting gasket to hold it in place during assembly and install in fuel ring groove.
3. Install fuel tank sending unit and pump assembly carefully to ensure that filter is not damaged. Ensure locating keys are in keyways and fuel pump mounting gasket remains in groove.

Fuel Tank Sensor And Pump Removal And Installation:

4. Hold fuel tank sending unit and pump 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 the fuel tank sending unit and pump unit by rotating the fuel pump locking retainer ring clockwise using Fuel Tank Sender Wrench D90P-9275-A or equivalent, until ring stops against stops.

CAUTION: Make sure that fuel tank shields are installed and positioned correctly.

6. Connect fuel hoses and tubes. Position fuel tank and secure with fuel tank support straps.
7. Connect fuel tank filler pipe.
8. Connect exhaust pipe.
9. Lower vehicle.
10. Install a minimum of 38 liter (10 gal) of fuel and check for leaks.
11. Install EFI and CFI Fuel Pressure Gauge T80L-9974-B on the fuel charging assembly fuel pressure relief valve. Turn ignition switch from OFF to ON position for three seconds. Turn ignition switch for three seconds repeatedly (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.
12. Remove pressure gauge. start engine, and check for leaks.