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.

This pressure must be relieved before servicing fuel system. Attach EFI and CFI Fuel Pressure Gauge T8OL-9974-B or equivalent to fuel diagnostic valve on fuel rail assembly if provided. Pressure in fuel system may now be released.

Removal






1. Place vehicle on hoist, do not raise.
2. Depressurize fuel system as follows:
a. Disconnect electrical connector at inertia switch.
b. Crank vehicle for a minimum of 15 seconds to reduce fuel pressure in lines.
3. Remove fuel from fuel tank by pumping out through filler. Use care to prevent combustion from fuel spillage.
4. Raise vehicle on hoist.
5. Disconnect and remove fuel filler tube.
6. All-Wheel Drive vehicles only: Remove exhaust system.
7. All-Wheel Drive vehicles only: Remove rear axle assembly.
8. 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 bench.
9. Remove any dirt that has accumulated around fuel pump attaching flange so that it will not enter fuel tank during removal and installation.
10. Turn fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9257-A or an equivalent, and remove lock ring.

NOTE: Perform Steps 11 and 12 for conventional vehicles and Steps 13 through 17 for All-Wheel Drive vehicles.

11. Remove fuel pump and bracket assembly.
12. Remove seal gasket and discard.
13. All-Wheel Drive vehicles only: Partially lift up sender unit. Disconnect jet pump line and electrical connector to resistor.
14. Remove fuel pump and bracket assembly.
15. Remove seal gasket and discard.
16. All-Wheel Drive vehicles only: Remove jet pump assembly attaching screw.
17. All-Wheel Drive vehicles only: Remove jet pump assembly.

Installation

1. Clean fuel pump mounting flange and fuel tank mounting surface and seal ring groove.
2. Put a light coating of Long-Life Lubricant C1AZ-19590-BA (ESA-M1C75-C) or equivalent on a new seal ring to hold it in place during assembly and install it in fuel ring groove.
3. All-Wheel Drive vehicles only: Install jet pump assembly and attaching screw. Tighten screw to 14-20 Nm (10-15 lb-ft).
4. Install fuel pump and sender assembly carefully to ensure that nylon filter is not damaged. Ensure that locating keys are in keyways and seal ring remains in place.
5. All-Wheel Drive vehicles only: Connect jet pump line and electrical connector to resistor. Ensure locating keyways and seal ring remain in place.
6. Hold assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.
7. Secure unit with locking ring by rotating ring clockwise using Fuel Tank Sender Wrench D84P-9275-A or an equivalent until ring stops against stops.
8. Remove fuel tank from bench to vehicle and support tank while connecting fuel lines, vent line and electrical connectors to appropriate places.
9. Install tank in vehicle and tighten straps.
10. All-Wheel Drive vehicles only: Install rear axle assembly.
11. All-Wheel Drive vehicles only: Install exhaust system.
12. Lower vehicle.
13. Install filler tube and attaching screws.
14. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
15. Recheck fuel pressure.
16. Remove pressure gauge, start engine, and recheck for leaks.