Fuel pump system replacement

Good morning,

Below are the instructions for dropping the fuel tank and removing the fuel pump assembly.

The part is available from Rockauto for a lot less than te parts stores.

Roy

REMOVAL PROCEDURE

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. See: Fuel Pressure Release > Procedures > Fuel System Pressure Relief
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. See: Fuel Tank > Procedures > Fuel Tank Draining

3. Remove the fuel tank (4).

IMPORTANT:
The modular fuel sender assembly may spring up.
When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender O-ring and replace the O-ring with a new O-ring.
Carefully discard the reservoir fuel into an approved container.

4. Use the J 39765 Fuel Sender Lock Nut Tool in order to press down and rotate the cam lock ring (1).
5. Remove the modular fuel sender assembly.
6. Remove the fuel level sensor.

INSTALLATION PROCEDURE

1. Install the fuel level sensor.
2. Install the O-ring on the fuel tank (4).
3. Align the fuel lines parallel with the mark on the fuel tank.
4. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.

IMPORTANT: Be sure that the cam lock ring is fully seated within the tab slots.

5. Install the cam lock ring using the J 39765 Fuel Sender Lock Nut Tool.
6. Install the fuel tank.
7. Lower the vehicle.
8. Fill the fuel tank and install the fuel filler cap.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

9. Reconnect the negative battery cable.
10. Inspect for fuel leaks using the following procedure:
10.1. Turn on the ignition for 2 seconds, leaving the engine off.
10.2. Turn off the ignition for 10 seconds.
10.3. Turn on the ignition, leaving the engine off.
10.4. Inspect for fuel leaks.