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.

Pressure must be relieved before servicing fuel system. Disconnect vacuum hose at fuel pressure regulator and attach Vacuum Pump D83L-7059-A or equivalent to allow fuel to return to tank. Pressure in fuel system may now be released.

Removal

1. Place vehicle on hoist. Do not raise.
2. Disconnect battery ground cable.






3. Disconnect fuel pump electrical connector (near RH rear lamp assembly). Remove grommet and wiring harness from luggage compartment.
4. Depressurize fuel system as outlined.
5. Remove fuel tank.
6. Remove any dirt that has accumulated around fuel pump attaching flange so it does not enter fuel tank during removal and installation.






7. Remove clamp. Unscrew fuel pump locking ring counterclockwise using Lock Ring Tool T88M- 9275-A or equivalent. Remove locking ring.
8. Remove fuel pump and sender assembly.
9. Remove seal ring and discard.

CAUTION: Installation of a used seal may result in improper sealing of tank, fuel pump and sender assembly.

Installation

1. Clean fuel pump and sender assembly mounting flange. Clean locking ring threads on fuel tank.
2. Loosely install new seal onto fuel pump and sender assembly mounting flange.
3. Install fuel pump and sender assembly carefully to ensure that filter and sender float arm are not damaged. Do not lower flange onto fuel tank without seal. Instead, assemble seal around locking ring threads. Ensure that seal fits evenly around its circumference.
4. Loosely assemble lock ring over pump wiring. Ensure that arrows on pump and fuel tank align with each other.
5. Push pump and sender assembly downward against loading spring until flange touches seal. Visually verify that seal edge is visible around circumference of flange and tank top. Rotate lock ring clockwise while holding down pump.
6. Secure unit with lock ring by rotating ring clockwise with Lock Ring Tool 188M-9275-A or equivalent.
7. Install lock ring clamp.
8. Carefully route surplus pump and sender unit wiring back and forth across top of fuel tank. Retain wiring with clips provided.
9. Install fuel tank.
10. Lower vehicle.
11. Connect pump and sender assembly wiring. Connect battery ground cable.
12. Install a minimum of 38 liters (10 gallons) of fuel and check for leaks.
13. Turn ignition key to RUN (position II) for three seconds repeatedly (5 to 10 times) to build up system pressure. Check for leaks at fittings.