Fuel Pump: Service and Repair

CAUTION: Do not perform these procedures while smoking, near any open flame, electrical contacts or other potential source of ignition.

Fuel Pump Fuse Location:

1. Release fuel pressure:
^ Remove fuse for fuel pump.
^ Start engine.
^ After engine stops, crank engine two or three times to make sure that fuel pressure is released.
^ Turn ignition switch off and install fuse for fuel pump.
2. Remove rear seat bottom and back cushion.

Fuel Pump Replacement Procedures:

3. Remove inspection hole cover.

CAUTION: Use rubber gloves to prevent fuel from contacting the skin when removing the fuel hoses and pump.

TECH TIP: The sheet metal for the top of the fuel tank is REALLY SHARP! One way to protect yourself is to take some door edge moulding and apply it to the lip of the tank opening. Vacuum hose sliced lengthwise will work too.

4. Disconnect electrical connector and fuel hoses.
5. Remove the lock ring. Be careful not to damage the cap. (Use SST X38879)
6. Remove fuel gauge sending unit and disconnect the fuel hoses and connector.

Fuel Pump Removal:

7. Remove fuel pump from fuel pump as shown in the figure.

Fuel Pump Replacement/Alignment Mark:

8. Installation procedure is the reverse order of removal, noting the following:
^ Pay attention to the alignment marks for the cover.
^ Always replace fuel tank O-ring with a new one.
^ Verify the two hoses to the plastic cover plate are installed correctly. The engine won't run if the hoses are reversed.
^ After installation, run engine and check for leaks at connections. Also verify the fuel gauge works.