Removal & Installation
- Before servicing the vehicle, refer to the Precautions section.
- Properly relieve the fuel system pressure.
- Disconnect the negative battery cable.
- Raise and safely support the vehicle.
Remove the fuel tank as follows:
- Drain the fuel from the tank.
- Remove the filler protector.
- Disconnect the filler tube.
- Detach any electrical connectors related to the fuel pump and fuel level sending unit.
- Detach the fuel line quick connectors.
- Safely support the fuel tank.
- Remove the tank mounting straps, then lower the tank out of the vehicle.
- Remove the 6 fuel pump bolts.
- Lift the fuel pump out of the fuel tank. Use care. The fuel level sensor and fuel pump and bracket must be tipped to remove it from the fuel tank. Do not lift the fuel sensor and pump assembly straight out of the fuel tank or damage to the level sensor may occur.
- Remove the 2 bolts attaching the level sensor to the fuel pump.
- Remove the fuel pump level sensor and the gasket.
- Discard the gasket.
Remove the fuel pump from the bracket.
- Position the fuel level sensor on the fuel pump and bracket and install the 2 bolts.
- Install a new level sensor gasket. Carefully install the level sensor and pump assembly.
- Install the 6 fuel pump bolts. Do not over-tighten the bolts. Tighten the bolts to just 17-23 inch lbs. (2-3 Nm).
- Install the fuel tank in the reverse order of removal, be sure to tighten the tank mounting straps to 20-26 ft. lbs. (27-35 Nm).
- Lower the vehicle. Refill the fuel tank as required.
- Connect the negative battery cable. Verify that the fuel pump relay has been properly installed. Start the engine and check for proper operation.
The fuel pump and fuel tank sending unit are removed as an assembly.
- Remove the fuel tank. Please refer to Fuel Tank, Removal and Installation for the procedure.
- Clean the area around fuel pump.
Remove the six fuel pump bolts.
WARNINGThe fuel pump and fuel tank sending unit assembly must be tilted to remove it from the fuel tank. Do not lift the assembly straight out of the tank, or damage may occur to the sending unit.
- Lift the fuel pump and fuel tank sending unit assembly from the fuel tank and discard the gasket.
- Install a new gasket and carefully lower the fuel pump and fuel tank sending unit assembly into the fuel tank.
- Install the six bolts and tighten them to 18-21 inch lbs. (2.0-2.4 Nm).
- Install the fuel tank.
- Add a minimum of 10 gallons (38 liters) of clean fuel to the tank.
- Cycle the ignition switch several times from the OFF to ON positions without starting the engine, allowing five seconds at each position, to build fuel pressure within the system. Check for fuel leaks.
Start the engine and recheck for fuel leaks. Road test the vehicle and check for proper operation.
If there is no fuel pressure or the pressure is low, and the in-line filter is not restricted, check the fuel pump as follows:
- Raise and safely support the rear of the vehicle securely on jackstands.
- Disconnect the fuel pump electrical connector.
- Connect the positive lead of a voltmeter to the light green and red wire terminal of the harness connector.
- Connect the negative voltmeter lead to the negative battery terminal or chassis ground.
- Without starting the engine, turn the ignition switch on and observe the voltmeter reading within five seconds. If the voltage is greater than 10 volts, proceed with the next step. If the voltage is less than 10 volts, check fuel pump fuse, relay, and related circuits, and repair as needed.
- Turn the ignition switch OFF and disconnect the voltmeter.
- Connect ohmmeter leads between the black and white wire terminal of the harness connector and the negative battery terminal or chassis ground.
- Observe the ohmmeter reading. If the reading is less than 5 ohms, proceed with the next step. If the reading is greater than 5 ohms, check the inertia fuel shutoff switch and related circuit, and repair as needed.
- Connect ohmmeter leads between the light green and red wire terminal and the black and white wire terminal of the fuel pump connector.
- Observe the ohmmeter reading. The reading should be 0.2-5.0 ohms. If not, replace the fuel pump.
If the fuel pump voltage supply, ground circuit, and resistance are within specifications, but the fuel pressure is below specifications, replace the pump.