FUEL PUMP REPLACEMENT INSTRUCTIONS
NOTE: The word "module" used throughout these instructions means fuel pump module.
I. PREPARATIONS
A)
Relieve fuel system pressure. (This procedure is necessary since the fuel system can
retain gasoline under pressure for a considerable period of time. Opening a pressurized
line could spray fuel creating a risk of fire and/or personal injury.)
1)
Start the engine.
2)
Remove the fuel pump relay allowing the engine to run until it quits. When the en-
gine quits, the fuel system pressure has been relieved. Turn the ignition switch off.
3)
Remove the battery ground (-) cable for safety.
4)
Reinstall the fuel pump relay.
ll. REMOVE FUEL TANK
A)
First make sure an appropriate fire extinguisher (Class B flammable liquids designation,
as a minimum) is at hand. Then using an OSHA approved gasoline transfer pump, re-
move as much fuel as pos-
sible through the fuel tank
filler neck. Store the fuel in
approved safety containers
only.
B)
There are several connec-
tions to the fuel tank, both
electrical and fuel lines, that
need to be disconnected
before the fuel tank can be
removed. Some of these
connections are reached
from inside the trunk of the
vehicle. Please refer to the
vehicle service manual for
specific instructions for
disconnecting these items
and removing the fuel tank.
III. REMOVE MODULE FROM
FUEL TANK
Some vehicles have two fuel pump
modules. Refer to the vehicle
service manual for tests to perform
to determine which fuel pump module is faulty.
A)
Remove locking ring from evaporative loss flange, (see Fig. 1).
B)
Lift flange from fuel tank and disconnect fuel pump wiring harness from underside of
flange.
C) Remove flange and tank seal. KEEP THE SEAL, IT WILL BE REUSED!
WARNING: Sparks may occur!
The following steps are to be performed inside the fuel tank. Any tools used inside the fuel tank
should be non-ferrous (brass or non-metal preferred) so that the possibility of sparks occurring
can be eliminated!
D) Reach inside the fuel tank and loosen the hose clamp from the faulty module.
E)
Remove the module and rubber mounting boot from the support bracket that is in the
tank. Note that the rubber mounting boot has one smaller slot that determines the orien-
tation of the boot in the support bracket.