REMOVAL & INSTALLATION
In-Tank Mount Type
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times
- Disconnect the negative battery cable. Relieve fuel pressure. Remove the filler cap.
- Using a siphon or pump, drain the fuel from the tank and store it in a proper metal container with a tight cap.
- On most models, remove the electrical connection at the top of the fuel tank assembly. If necessary remove the rear seat cushion to gain access to the electrical wiring connector.
- Disconnect the fuel pump and sending unit wiring at the connector.
- Raise the vehicle and safely support it on jackstands.
- Loosen the clamp and remove the filler neck and overflow pipe from the tank.
- Remove the supply hose from the tank. Wrap a rag around the fitting to collect escaping fuel. Disconnect the breather hose from the tank, again using a rag to control spillage.
- Cover or plug the end of each disconnected line to keep dirt out and fuel in.
- Support the fuel tank with a floor jack or transmission jack. Use a broad piece of wood to distribute the load. Be careful not to deform the bottom of the tank.
- Remove the fuel tank support strap bolts.
- Swing the straps away from the tank and lower the jack. Balance the tank with your other hand or have a helper assist you. The tank is bulky and may have some fuel left in it. If its balance changes suddenly, the tank may fall.
- Remove the fuel filler pipe extension, the breather pipe assembly and the sending unit assembly. Keep these items in a clean, protected area away from the car.
To separate the electric fuel pump:
- Disconnect the two pump-to-harness wires.
- Loosen the pump outlet hose clamp at the bracket pipe.
- Remove the pump from the bracket and the outlet hose from the bracket pipe.
- Separate the outlet hose and the filter from the pump.To install:
- While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank. Clean the inside of the tank with water and a light detergent, then rinse the tank thoroughly several times.
- Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
- When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing signs of deterioration.
- Assemble the outlet hose and filter onto the pump; then attach the pump to the bracket.
- Connect the outlet hose clamp to the bracket pipe and connect the pump wiring to the harness wire.
- Install the fuel pump and bracket assembly onto the tank.
- Install the sending unit assembly.
- Connect the breather pipe assembly and the filler pipe extension.
Tighten the breather pipe screw and all other attaching screws evenly
- Place the fuel tank on the jack and elevate it into place within the car. Attach the straps and install the strap bolts, tightening them (in even steps) to 29 ft. lbs. (39 Nm).
- Connect the breather hose to the tank pipe, the return hose to the tank pipe and the supply hose to its tank pipe. tighten the supply hose fitting to 21 ft. lbs. (28 Nm).
- Connect the filler neck and overflow pipe to the tank. Make sure the clamps are properly seated and secure.
- Lower the vehicle to the ground.
- Connect the pump and sending unit electrical connectors to the harness.
- Install the rear seat cushion, if necessary.
- Using a funnel, pour the fuel that was drained from its container into the fuel filler.
- Install the fuel filler cap.
- Start the engine and check carefully for any sign of leakage around the tank and lines. Road test the vehicle for proper operation.
See Figures 1, 2 and 3
- Turn the ignition switch ON , but do not start the engine.
- On early models, remove the rubber cap from the fuel pump check connector using a jumper wire, short both terminals of the fuel pump check connector. On late models (the check connector is located under the hood near the shock tower) connect the terminals labelled FP and B+ together in the check connector. Refer to the illustrations.
- Check that there is pressure in the hose running to the delivery pipe. You should hear fuel pressure noise and possibly hear the pump at the rear of the car.
- Remove the jumper wire.
Turn the ignition to
. If the fuel pump failed to function, it may indicate a faulty pump. On EFI vehicles, before removing the tank and pump, check the following items within the pump system:
- Fusible link.
- Fuses (EFI/15 amp and IGN/7.5 amp).
- Fuel injection main relay.
- Fuel pump circuit opening relay.
- All wiring connections and grounds.