Fuel Pump and Bracket Assembly

Tools Required:

• EFI and CFI Fuel Pressure Gauge Tool T80L-9974-B
• Fuel Tank Sender Wrench D84P-9275-A
• Rotunda Fuel Storage Tanker 034-00002
• Adapter Hose 034-00012

Removal

1. Place vehicle on hoist, do not raise.

2. Depressurize fuel system as outlined under Fuel System Pressure Relief.

    WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUT DOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. A VALVE IS PROVIDED ON THE FUEL CHARGING ASSEMBLY FOR THIS PURPOSE. REMOVE THE AIR CLEANER. ATTACH EFI AND CFI FUEL PRESSURE GAUGE T80L-9974-B OR EQUIVALENT TO THE FUEL DIAGNOSTIC VALVE ON THE FUEL CHARGING ASSEMBLY. PRESSURE IN THE FUEL SYSTEM MAY NOW BE RELEASED.

3. Drain fuel tank through filler neck using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00012 or equivalent.

4. Raise vehicle on hoist. Refer to Section 00-02.

5. Disconnect and remove fuel filler tube.

6. Remove fuel tank support straps and support fuel tank in vehicle. Remove fuel lines, vent hose and electrical connector before moving tank to bench.

7. Remove any dirt that has accumulated around the fuel pump retaining flange so that it will not enter the tank during removal and installation.

8. Turn the fuel pump locking ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, and remove locking ring.

9. Remove fuel pump and bracket assembly.

10. Move tank to bench.

11. Remove seal gasket and discard.

Installation

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.

2. Apply a light coating of Premium Long-Life Grease XG-1-C (ESA-M1C75-B) or equivalent on a new seal ring to hold it in place during assembly and install in fuel ring groove.

3. Install fuel pump and bracket assembly carefully to ensure that filter is not damaged. Ensure locating keys are in keyways and seal ring remains in groove.

4. Hold pump assembly in place and install locking ring finger-tight. Ensure that all locking tabs are under tank lock ring tabs.

5. Secure the fuel pump unit by rotating the locking ring clockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent, until ring stops against stops.

6. Connect fuel hoses and tubes. Install fuel tank and secure with retaining straps.

7. Lower vehicle.

8. Install filler tube and retaining screws.

9. Install a minimum of 38 L (10 gal) of fuel and check for leaks.

10. Install EFI and CFI Fuel Pressure Gauge T80L-9974-B or equivalent on the fuel charging assembly fuel diagnostic valve. Turn ignition switch from OFF to ON position for three seconds. Turn ignition switch for three seconds repeatedly (5 to 10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.

11. Remove pressure gauge, start engine and check for leaks.
    
    
    
    
    

    Item	Part Number	Description
    1	9A340	Wiring Assembly
    2	9C385	Fuel Pump Locking Retainer Ring
    3	9350	Fuel Pump
    4	9276	Fuel Tank Sending Unit Gasket
    5	9002	Fuel Tank
    6	—	Stop
    7	—	Tab
    8	—	Detent