REMOVAL & INSTALLATION
The fuel pump and sending unit are one assembly, located in the fuel tank. In almost every case, the fuel tank must be removed in order to access the pump/sending unit assembly. Do not kink or twist fuel hoses or lines. Use new gasoline fuel hose clamps if possible.
- Before disconnecting the fuel lines or any of the fuel system components, release the fuel system pressure as described previously in this section. Reducing the fuel pressure a very important step for correct removal of the electric fuel pump/sending unit assembly.
- Disconnect the negative battery cable.
- Unfasten the fuel pump/gauge sending unit assembly electrical connector, then remove the fuel tank inspection cover.
If the truck has no fuel tank inspection cover, the fuel tank must be lowered or removed to gain access to the in-tank fuel pump.
- Disconnect the fuel outlet and return hoses. Remove the fuel tank assembly, if necessary.
- Remove the ring retaining bolts and the O-ring, then lift the fuel pump/sending unit assembly from the fuel tank. Plug the opening with a clean rag to prevent dirt from entering the system.
When removing or installing the fuel pump/sending unit assembly, be careful not to damage or deform it. Always install a new O-ring.To install:
- Install the fuel pump/sending unit assembly in the fuel tank with a new O-ring, then install the ring retaining bolts.
- If removed, install the fuel tank. If not, install the fuel tank inspection cover.
- Reconnect the fuel lines and fasten the electrical connection.
- Connect the battery cable, then start the engine and check the fuel gauge for proper operation.
The "Check Engine Light'' may stay on after installation is completed. If so the trouble code stored in the control unit's memory must be erased. To erase the code, disconnect the battery cable for 10 seconds, then reconnect it and verify that the light has extinguished.