Preparations: Fuel systems are under pressure. It is necessary to relieve the fuel system pressure before beginning work on the fuel system. Relieving the pressure can be done by removing the fuel cap.
- Locate and remove the fuel pump fuse from the fuse block.
- After the fuse is removed, start the engine and let the engine consume the remaining gasoline in the fuel lines. The engine will stop when remaining fuel is consumed.
- Once the engine has stopped, crank the engine for three seconds to relieve any possible remaining fuel pressure.
Disconnect the vehicles negative/ground cable at the battery and secure it so that it will not accidentally make a connection while replacing the fuel pump.
Drain the gasoline from the vehicle’s fuel tank
- Using only an OSHA approved gasoline transfer pump and approved fuel storage containers, remove as much gasoline as from the fuel tank through the filler neck.
- Raise the vehicle with an automotive hoist or jack up the vehicle and support it with OSHA approved jack stands, which allow unobstructed clearance for the removal of the fuel tank.
- Fuel tank gasoline levels will vary depending on the amount of gasoline removed through the filler neck. Once the vehicle is raised, additional gasoline can be removed through bracket connections.
ATTENTION: Because of physical size and weight of vehicle fuel tanks, it is necessary to obtain help when removing the fuel tank from the vehicle. Take extra precautions to avoid gasoline spillage during the removal process.
Fuel Tank Removal
Fuel tanks vary from vehicle to vehicle; the following fuel tank removal instructions are for a typical fuel tank removal. For more specific instructions on fuel tank removal for your specific vehicle it may be necessary to obtain an approved Service Manual for the vehicle that you are replacing the fuel pump on.
- Visually inspect the scope of work involved before beginning the fuel tank removal step. Be sure to have help readily available.
- Disconnect all visible fuel hoses that connect to the fuel tank from the rest of the vehicle (be sure to mark or label all connections for reassembly).
- Disconnect electrical connections at the fuel tank taking extra care not to damage pins or connectors.
- If necessary, disconnect and remove the fuel filler neck from the vehicle.
- Loosen the retaining straps of the fuel tank and support the fuel tank prior to removing the straps entirely. Take extra precautions to avoid a fuel spill.
- Take note of the condition and location of any insulating pads. Worn or misaligned, wrongly installed pads should be replaced as they may affect the performance of the new fuel pump.
- Before removing the bracket from the fuel tank, be sure to thoroughly clean any dirt or debris that may have accumulated at the top of the fuel tank or at the opening of the locking ring area. This step must be done to prevent debris or foreign matter from entering the fuel tank which can cause problems later on.
- Using the correct tools, remove the locking ring or retainer using care not to damage it.
- Carefully lift out the bracket from the fuel tank. The old o-ring seal must be removed using extra care not to let pieces fall into the tank as it may be brittle. Discard the old o-ring seal; it will be replaced with a new o-ring seal which is included in the kit.
Replacement of the Pump
- Replace the pump and filter as directed in the instructions that accompany the kit.
- Ensure that all connections are secure before installation into the fuel tank.
- Before bracket reinstallation, carefully inspect the inside of the fuel tank for contamination, dirt or foreign matter. Clean out the fuel tank if necessary prior to bracket reinstallation.
- Ensure the bracket is fully assembled and ready for installation.
- Install a new o-ring (not included in the kit) in the groove at the bracket opening. Carefully lower the bracket assembly into the fuel tank taking extra care not to bend or damage the float or the float arm. Be sure not to disturb the o-ring when seating the bracket while keeping the filter free of kinks and fold as this may restrict fuel flow.
- Reinstall the locking ring or retainer using the correct tools.
Reinstalling the Fuel Tank
- As mentioned in section II, worn insulation and mounting pads must be replaced. It is imperative that pads are installed in the same manor that they were removed as missing or wrongly installed pads will cause noise or vibration to the vehicle.
- Prior to lifting the fuel tank into place, ensure that all fuel lines and hoses sound. Replace any inferior or defective fuel lines or hoses.
- Support the fuel tank in the correct installation position. Once the fuel tank is in the correct position install the support straps and bolt in the same manner that they were removed.
- Reconnect all fuel lines and electrical connections securely ensuring that there are no kinks or perforations. Routing of fuel lines is especially important, so be sure to route fuel lines in the same
manner as before using all clips and securing devices provided by the manufacturer.
Finishing the Process
- Gasoline should only be reinstalled back into the vehicles fuel tank with an OSHA approved gasoline-dispensing device. Before moving to the next step, be sure to clean up any fuel that may have spilled during pump replacement or during the gasoline refilling process.
- At this time a visual inspection for leaks is necessary. Correct any leaks at this time prior to proceeding to the next step.
- Following the reverse order of the removal, reinstall the fuel pump fuse back into the fuse block and reconnect the negative/ground battery cable to the battery.
- Start the vehicle’s engine and inspect for any leaks. If leaks exist correct them immediately.
- Some vehicles are equipped with OBD (On board diagnostic) systems which may have illuminated a light indicating a trouble code of malfunction. Clear trouble codes using a service manual specific to the vehicle.
Should the Pump Fail to Operate
- Ensure that all electrical connections are secure.
- Check the fuel pump fuse as indicated in the vehicles Service Manual.
- Check the battery for proper power/polarity levels.
- Check the remainder of the fuel system for proper operation as outlined in the vehicles Service Manual.
Be advised that this fuel pump will not correct other vehicle malfunctions of the fuel system.