Fuel Pump Replacement Pump

Tools Required

1. Remove the fuel tank. Refer to Fuel Tank Removal.




Caution: Whenever fuel line fittings are loosened or removed, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

Notice: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

2. Disconnect fuel lines from the fuel pump module cover.

Notice: To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.

3. Use the J 43827 and remove the fuel pump module retaining ring. A 1/2 in. breaker bar, approximately 45.7 cm (18 in) long, will easily loosen and remove the lock ring.



4. To prevent bending of the sending unit float arm, remove the sending unit first by pulling the retaining clip toward the float arm and lift upward.



5. Carefully lift the fuel pump straight up from the fuel tank. To disengage the fuel pump from the fuel pump housing, the clips must be disengaged at the same time.

Important: Always replace the fuel pump module to tank seal, O-ring, whenever the assembly is removed.

6. Discard the fuel pump module to tank seal.



7. Remove the fuel feed line from the bottom of the fuel pump cover the using the J 43914 .



8. Disconnect the fuel pump electrical connector from the fuel pump cover.
9. Inspect the fuel tank for metal chips/debris. Remove all contaminants and replace the in-line fuel filter before installing a new fuel pump assembly when debris is present.

1. Connect the new fuel pump feed line to the fuel pump cover using the J 43914 .



2. Connect the fuel pump electrical connector to the fuel pump connector.



3. Insert the new fuel pump to fuel tank seal.



4. Use the J 43827 to install the fuel pump cover lock ring. The bumps on the lock ring need to be facing away from the tank.



5. Connect the fuel lines and wiring harness.
6. Install the fuel tank. Refer to Fuel Tank Installation.

Fuel Pump Replacement Module

Tools Required

J 43827 Fuel Sending Unit Wrench

1. Remove the fuel tank. Refer to Fuel Tank Removal.

Notice: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.

2. Disconnect the fuel lines from the fuel pump module cover.




Notice: To prevent retainer damage, do not attempt to remove the retainer with a 12 in. or shorter ratchet/breaker bar.

3. Use the J 43827 and remove the fuel pump module retaining ring. A 1/2 in. breaker bar, approximately 45.7 cm (18 in) long, will easily loosen and remove the lock ring.



4. To prevent bending of the sending unit float arm, remove the sending unit first by pulling the retaining clip toward the float arm and lift upward.
5. Carefully lift the fuel pump straight up from the fuel tank. To disengage the fuel pump from the fuel pump housing (4), the clips must be disabled at the same time.

Important: Always replace the fuel pump module to tank seal, O-ring, whenever the assembly is removed.

6. Discard the fuel pump module to tank seal.



7. Remove the fuel housing by releasing the 4 retaining clips. The retaining clips hold the fuel pump housing to the fuel pump housing bracket, mounted in the bottom of the tank.

7.1.

Disengage the clip closest to the pump, where the fuel return line attaches to fuel pump housing, by inserting a small flat blade screwdriver between the clip, on the housing, and the mounting bracket. Leave the screwdriver wedged in place to prevent the clip from reattaching as the other clips are being disabled.

7.2.	Disengage the clip closest to the one disengaged in the previous step, toward the rear of the tank. Use a second small flat blade screwdriver to disenable this clip.





7.3.	Stick one of the screwdrivers between the fuel pump housing and base of the fuel tank to prevent the clips, in the previous steps, from re-engaging. Remove the second screwdriver from the fuel tank.





7.4.	The next clip to be disengaged is at the rear most position. To disengage this clip, tilt the housing toward the jet pump while releasing this clip.

7.5.	Once these clips have been disengaged push the module, or roll the module, in the direction of the remaining clip that is engaged. This will force the clip to disengage.

7.6.	Remove the housing from the tank.

Important: Inspect the fuel tank for metal chips/debris. Remove all contaminants and replace the in-line fuel filter before installing a new fuel pump assembly when debris is present.

1. Install the new fuel pump and housing straight down into the fuel pump housing bracket. The jet pump needs to be toward the front of the tank on the drivers side. Make sure all the clips engage.



2. Install the fuel sender into the fuel pump housing and connect its connector to the fuel pump cover



3. Insert the new fuel pump to fuel tank seal.



4. Use the J 43827 to install the fuel pump cover lock ring. The bumps on the lock ring need to be facing away from the tank.



5. Connect the fuel lines an wiring harness.
6. Install the fuel tank. Refer to Fuel Tank Installation.