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. Depressurize fuel system.
2. Drain fuel tank.
3. Raise vehicle on a hoist.
4. Disconnect and remove fuel tank filler pipe.
5. Support fuel tank and remove fuel tank support straps. Lower fuel tank partially and disconnect fuel lines, electrical connectors and fuel vapor and vent lines from fuel tank. Remove fuel tank to bench.
6. Remove any dirt that has accumulated around fuel tank sending unit and pump so that dirt does not enter fuel tank during fuel tank sending unit and pump removal.






7. Remove fuel pump locking retainer ring using Fuel Tank Sender Wrench D90P-9275-A or equivalent.
8. Lift fuel tank sending unit and pump locating tabs from fuel tank location slots.






9. Lift fuel tank sending unit and pump upward rotating left, while aligning float wiper arm retainer and return line into fuel tank location slots.






10. Apply slight pressure to remove fuel tank sending unit and pump.






11. Lift float wiper arm through LH fuel tank slot and pass pump motor retaining bracket through the RH fuel tank slot.






12. Remove fuel tank sending unit and pump keeping return line in fuel tank slot. Lift fuel pump inlet filter then sender arm float through fuel tank opening.
13. Remove fuel methanol compatible fuel pump mounting gasket (9417).
14. To install, position new fuel methanol compatible fuel tank sending unit and pump gasket and reverse Remove procedure






15. To install fuel tank, reverse Removal procedure. Start engine and check for leaks.