Fuel Pump: Service and Repair

***UPDATED BY TSB # 92-30-006, DATED DECEMBER 1992

WARNING: This procedure involves working with parts associated with gasoline delivery. Even though the gasoline may be drained from the parts, some gasoline and/or gasoline vapors may remain. Do not smoke or bring parts into an area where an open flame or spark could ignite the gasoline or gasoline vapors. Serious bodily injury may result if gasoline or vapors ignite. When service procedures involve gasoline suitable fire extinguishing equipment should be available in the area.

REMOVAL
1. Disconnect the fuel pump connector.
2. Start and run the engine until it stalls, then turn the ignition switch to OFF.
3. Disconnect the battery negative terminal.
4. Remove the fuel tank cap.
5. Drain the fuel.
6. Disconnect the fuel high pressure hose.

CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.

Fuel tank removal is required to service the fuel pump. For these procedures refer to FUEL TANK, under the appropriate paragraph heading.

Fuel Pump Mounting Screws:

After fuel tank removal, remove the fuel pump installation screws, then remove the pump from the fuel tank.

Note: It is not necessary to replace the complete fuel strainer-pump-pickup assembly when a malfunction occurs in the fuel pump motor. The fuel pump motor is available as a separate replacement part.

7. Remove the fuel pump as an assembly, as described above.
8. Remove the fuel pump filter.



9. Disconnect the insulated wire connector.



10. Using a soldering iron, disconnect the second non-insulated connector from the fuel pump.

WARNING: DO NOT USE A FLAME TYPE SOLDERING IRON!

11. Remove the fuel pump from its bracket.

Note: It may be necessary to bend the bracket "ears" slightly to remove the pump from the bracket.




12. Disconnect the fuel hose from the fuel pump.




13. Remove the rubber insulator from the fuel pump.
14. Reverse the order of removal to reinstall.

Note: The non-insulated connector connects to the negative (-) terminal of the fuel pump. The insulated connector connects to the (wider) positive (+) pump terminal.





WARNING: The non-insulated connector MUST BE SOLDERED to the fuel pump when reconnected. If the connector is not soldered, the potential for EXPLOSION AND FIRE of the fuel tank exists when the fuel pump is powered.

INSTALLATION

Fuel Pump Positioning Projections:

1. Install the gasket, taking care to properly align it with the three positioning projections.
2. As the fuel pump is re-installed, align the three positioning projections with the holes in the fuel pump. Care should be taken at this time to insure that the gasket is properly seated.

Torque: 1.4-2.2 Nm (2-3 ft lb)

3. Install the fuel tank, refer to FUEL TANK, under the appropriate paragraph heading.