Fuel Pump: Service and Repair

Fuel Pump And Components:

REMOVAL:

1. Disconnect the negative battery terminal.
2. Remove rear seat cushion.
3. Disconnect the fuel pump and fuel gauge sender unit connector.
4. Remove the five service hole cover screws.

Removing Fuel Pump Access Cover:

5. Remove the fuel filler cap.
6. Disconnect the fuel pipe union bolt and return hose from the fuel pump bracket.

Removing Fuel Lines From Fuel Pump Bracket:

7. Remove the eight fuel pump bracket screws.

Removing Fuel Pump Bracket From Fuel Tank:

8. Pull the bracket and fuel pump out through the service hole.

Extracting Fuel Pump And Bracket Assembly From Fuel Tank:

9. Remove the bracket gasket from the tank and discard.
10. Remove the nut and spring washer, and disconnect the lead wire from the pump bracket.
11. Disconnect the three lead wires.
12. Remove the two screws and sender unit.

Remove Fuel Sender Gauge From Bracket Assembly:

13. Pull the lower side of the pump from the bracket.

Remove Fuel Pump From Bracket Assembly:

14. Remove the two nuts from the fuel pump wires and remove the fuel hose from the top of the fuel pump.
15. Remove the fuel pump from the bracket.
16. Remove the rubber cushion from the fuel pump and using a small screwdriver, remove the clip that holds the filter screen to the fuel pump pick-up.

Remove Fuel Pump Filter Screen From Fuel Pump:

17. Pull the fuel screen from the fuel pump.

INSTALLATION:

Fuel Pump Assembly:

1. Install the fuel screen into the new fuel pump and secure it with a new clip.
2. Install the rubber cushion on the bottom of the fuel pump.
3. Connect the fuel hose, (still in the bracket), to the outlet port of the fuel pump.
4. Connect the wires to the fuel pump with the nuts, ensuring proper electrical polarity.
5. Push the lower side of the fuel pump into the fuel pump bracket, ensuring that the fuel screen locks into the bracket securely.
6. Install the sending unit with the two screws.
7. Connect the three lead wires.

Correct Location For Three Lead Wires:

8. Install the fuel pump and bracket with new gasket into the fuel tank using the eight screws.
9. Torque the screws evenly to 2.1 ft.lbs. (2.9 Nm).
10. Connect the outlet fuel pipe and return hose to the bracket.
Torque the union bolt to 22 ft.lbs. (29 N-m).
11. Install fuel filler cap.
12. Install rear seat cushion.
13. Reconnect the negative battery terminal.