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Fuel Pump Replacement Instructions
NOTE: The words “tank unit” used throughout these instructions mean fuel pump module
assembly including flange, bucket, hoses, and level sender.
I. PREPARATIONS
A) Relieve fuel system pressure.
NOTE: The fuel system can retain gasoline under pressure for a con siderable period of time.
Opening a pressurized line could spray fuel creating a risk of fire and personal Injury.
1. Remove fuel cap from the tank to relieve any tank pressure.
2. Locate the power distribution block and remove the fuel pump relay. Relay locations
are described inside the cover of the power distribution block.
3. With the fuel pump relay removed, crank the engine to bleed down fuel system
pressure. The engine will start and stall several times. Continue to momentarily crank
the engine several more times. Be sure to turn the ignition switch completely to the
off position between cycles. Once the engine no longer tries to start, the fuel system
pressure is relieved.
B) Disconnect the negative (-) cable from the battery and position it so it cannot make ANY
accidental contact to ground during the fuel pump replacement process.
NOTE: Be sure an appropriate fire extinguisher is readily accessible before continuing with the
service procedure.
C) Drain the fuel tank with an OSHA approved gasoline transfer pump. Place the suction
hose of the pump into the fuel tank through the filler neck.
NOTE: Be sure the hose is completely inserted into the tank. All of the fuel must be drained
before trying to remove the fuel tank.
II. FUEL TANK REMOVAL
A) Remove the fuel filler and vent hoses from the fuel tank.
B) Remove any shields that may interfere with removal of the fuel tank (if so equipped).
C) Support the fuel tank and remove the tank retaining straps.
D) Remove the fuel filler neck hose and tank vent hose.
E) Lower the fuel tank enough to access the top of the fuel tank.
F) Remove the fuel line connector safety retainers. Disconnect the fuel lines.
G) Remove any other lines and electrical connections from the tank.
H) Carefully lower the fuel tank out of the vehicle.
III. REMOVE THE TANK UNIT FROM THE FUEL TANK
A) Thoroughly clean the top of the fuel tank to prevent any dirt from getting into the fuel tank
when the pump bracket is removed.
WARNING: Have absorbent shop towels readily available when removing the pump
bracket. Some fuel will spill when tank unit is removed.
B) Remove the tank unit ring from the tank.
C) Carefully remove the tank unit from the fuel tank. Be careful not to bend the float arm or
damage the float.
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