Astro, Safari 1997-2005

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Support the fuel tank.
  8.  
  9. Disconnect negative battery cable.
  10.  
  11. Disconnect filler neck from the tank.
  12.  
  13. Remove shield from tank and tank straps.
  14.  
  15. Disconnect fuel lines and vapor hose from pump.
  16.  
  17. Disconnect electrical connection from fuel pump.
  18.  
  19. Remove fuel tank.
  20.  
  21. Remove fuel pump/sending unit assembly by turning the locking ring (located on top of the fuel tank) counterclockwise using a spanner wrench.
  22.  
  23. Remove fuel pump from the fuel lever sending device.

    Click image to see an enlarged view

    Fig. View of the in-tank fuel pump assembly

  24.  

To install:

  1. Install fuel pump in tank with new seal around opening.
  2.  
  3. Raise tank and connect fuel lines and vapor hose.
  4.  
  5. Install tank to the frame. Torque the fasteners to 33 ft. lbs. (45 Nm).
  6.  
  7. Install shield.
  8.  
  9. Install fuel filler neck and clamp.
  10.  
  11. Connect negative battery cable.
  12.  
  13. Refill the tank.
  14.  
  15. Run the engine and check for leaks.
  16.  

 
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