Fuel Pump: Service and Repair

ELECTRIC PUMP

WARNING: The fuel injection system--if equipped--is under high pressure which must be relieved prior to opening the system.

Relieving System Pressure:
1. Remove the Fuel Pump fuse from fuse block, start and run engine until remaining fuel in lines is consumed.
2. Crank engine for approximately 3 seconds to ensure complete pressure relief, then turn off ignition and install fuse.

Replacement
1. Disconnect battery ground cable.
2. Raise and support vehicle. If vehicle is raised on center post type hoist, place suitable supports under front of vehicle to aid stability when fuel tank is removed.
3. Support fuel tank, then remove retaining straps and screw securing ground strap to chassis.
4. Lower tank, disconnect fuel and vapor lines and electrical connectors from sending unit, then remove tank from under vehicle.
5. Release cam lock retainer securing sending unit using a J-24187 or equivalent, then withdraw sending unit/pump assembly from tank.
6. Slide pump up into connector hose and separate pump from bottom retainer.
7. When pump clears bottom retainer, pull pump from connecting hose to remove.
8. Reverse procedure to install.

MECHANICAL PUMP

NOTE: To ease pump installation, rotate the camshaft so the camshaft eccentric is out of the way of the fuel pump rocker arm.

1. Disconnect fuel lines from fuel pump.
2. Remove fuel pump mounting bolts and the fuel pump.
3. Remove all gasket material from the pump and block gasket surfaces. Apply sealer to both sides of new gasket.
4. Position gasket on pump flange and hold pump in position against its mounting surface. Make sure rocker arm is riding on camshaft eccentric.
5. Press pump tight against its mounting. Install retaining screws and tighten them alternately.
6. Connect fuel lines. Then operate engine and check for leaks.