Fuel Pump: Service and Repair

FUEL PUMP AND SENDER ASSEMBLY

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. Remove fuel tank.
2. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the tank during removal and installation.
3. Turn the fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, and remove locking ring.
4. Remove fuel pump and bracket assembly.
5. Remove seal ring and discard.

Installation

Fuel Pump Hardware:

1. Clean the fuel pump mounting flange and the fuel tank mounting surface and seal ring groove.
2. Apply a light coating of Long-Life Lubricant C1AZ-1 9590-BA (ESA-M1C75-B) or equivalent on a new seal ring to hold it in place during assembly and install in fuel ring groove.
3. Install fuel pump and bracket assembly carefully to ensure that filter is not damaged. Ensure locating keys are in keyways and seal ring remains in groove.
4. Hold pump assembly in place and install locking ring finger- tight. Ensure that all locking tabs are under tank lock ring tabs.
5. Secure the fuel pump unit with the locking ring by rotating clockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, until ring stops against stops.
6. Install fuel tank.
7. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
8. Install Fuel Pressure Gauge T8OL-9974-B or equivalent on the fuel charging assembly fuel diagnostic 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.
9. Remove pressure gauge, start engine, and check for leaks.