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

CAUTION: The fuel system contains pressurized fuel after vehicle is shut down and will maintain this presure for a long of time.

Fuel Pump Relay:

1. Relieve the fuel pressure.
a. Start the engine.
b. Disconnect the fuel pump relay.
c. After the engine stalls, turn OFF the ignition switch.
d. Reconnect the fuel pump relay.

Fuel Pump Removal/Installation:

2. Remove fuel pump sending unit.

Fuel Pump - Exploded View:

3. Remove the fuel filter from pump.
4. Remove two fuel pump wires from the fuel pump motor.
5. Remove retaining clamp screws.
6. Remove pump outlet hose clamp.
7. Remove fuel pump from sending unit.
8. Remove the float assembly electrical connector from the sending unit.
9. Remove the attaching screws and washers.
10. Remove the float assembly.

INSTALLATION

1. Install the float assembly to the sending unit with attaching screws and nuts.
2. Install the float assembly electrical connector to the sending unit.
3. Install the fuel pump to sending unit bracket and secure with retaining clamp.
^ The rubber grommet must be seated between the fuel pump motor and the retaining bracket and the rubber insulator inserted between the bottom of the fuel pump motor and the sending unit bracket. Proper installation of this insulator will insure proper fuel pump motor installation.
4. Install pump outlet hose and secure with clamp.
5. Connect fuel pump wires to the fuel pump motor.
6. Install the low pressure side fuel pump filter.
7. Install sending unit onto fuel tank.