The fuel pump assembly is located in the fuel tank. Refer to the fuel tank assembly illustrations in this section. On most applications, the fuel tank must be lowered to remove the fuel pump assembly. The fuel pump assembly is cooled by the fuel in the tank.
REMOVAL & INSTALLATION
- Before disconnecting the fuel lines or any of the fuel system components, release the fuel pressure, as previously described in this section. Reducing the fuel pressure is a very important step for correct removal of the electric fuel pump.
- Disconnect the negative battery cable.
- Unfasten the fuel pump assembly electrical connector and 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 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 assembly, be careful not to damage or deform it. Always install a new O-ring.To install:
- Install the fuel pump assembly in the fuel tank with a new O-ring. Install the ring retaining bolts. Install the fuel tank if removed.
- Reconnect the fuel lines and fasten the electrical connection.
- Connect the battery cable, start the engine and check for fuel leaks.
The "Check Engine Light'' may stay on after installation is completed. If so, the trouble code in the control unit's memory must be erased. To erase the code, disconnect the battery cable for 10 seconds, then reconnect it a verify that the light is extinguished.
See Figure 1
- Relieve the fuel system pressure, described previously in this section.
- Disconnect the fuel inlet hose between the fuel filter and fuel line on the engine side.
- Install a fuel pressure gauge.
- Start the engine and check the fuel line for leakage.
- Read the pressure on the pressure gauge.
Pressure gauge should read as follows with pressure regulator vacuum hose connected:
KA24E engine-33 psi (228 kPa)
- Stop the engine and disconnect the fuel pressure regulator vacuum hose from the intake manifold. Plug the intake manifold with a rubber cap.
Start the engine. Pressure gauge should read as follows with pressure regulator vacuum hose disconnected:
KA24E engine-43 psi (296 kPa)
- Stop the engine. Connect a hand vacuum pump to the fuel pressure regulator.
- Start the engine and read the fuel pressure gauge as the vacuum is changed with the hand vacuum pump. Fuel pressure should decrease as vacuum increases. If not, replace the fuel pressure regulator.