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Fuel Pump

REMOVAL & INSTALLATION

Navajo and B Series Pick-up Models

NOTE: To gain access to the fuel pump, it is necessary to remove the fuel tank.

  1. Depressurize the fuel system and remove the fuel tank from the vehicle.
  2. Remove any dirt that has accumulated around the fuel pump attaching flange, to prevent it from entering the tank during service.
  3. Turn the fuel pump locking ring counterclockwise using a locking ring removal tool and remove the locking ring.
  4. Remove the fuel pump and bracket assembly.
  5. Remove the seal gasket and discard it.

    To install:

  6. Put a light coating of heavy grease on a new seal ring to hold it in place during assembly. Install it in fuel tank ring groove.

    Fig. 1: Fuel pump and sending unit used on the B Series Pick-up regular cab

    Fig. 2: Fuel pump and sending unit used on the B Series Cab Plus Pick-up

    Fig. 3: Fuel pump and sending unit used on the Navajo

  7. Insert the fuel pump assembly into the fuel tank, then secure it in place with the locking ring. Tighten the ring until secure.
  8. Install the tank in the vehicle.
  9. Install a minimum of 10 gallons of fuel and check for leaks.
  10. Install a pressure gauge on the throttle body valve and turn the ignition ON for 3 seconds. Turn the key OFF, then repeat the key cycle five to ten times until the pressure gauge shows at least 30 psi. Reinspect for leaks at the fittings.
  11. Remove the pressure gauge. Start the engine and check for fuel leaks.
MPV Models
  1. Relieve the fuel system pressure and disconnect the negative battery cable.
  2. Remove the rear seat and lift up the rear floormat. Remove the fuel pump cover.
  3. Disconnect the sending unit/fuel pump assembly electrical connector and the fuel lines.
  4. Remove any dirt that has accumulated around the sending unit/fuel pump assembly so it will not enter the fuel tank during removal and installation.
  5. Remove the attaching screws and remove the sending unit/fuel pump assembly.
  6. If necessary, disconnect the electrical connectors and the fuel hose and remove the pump from the sending unit assembly.
  7. Installation is the reverse of the removal procedure. Be sure to install a new seal rubber gasket.

    Fig. 4: Remove the rear seat and floormat to service the fuel pump

    Fig. 5: Removing the fuel pump assembly

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