After having identified the fuel pump as the cause of a failure, empty the fuel tank in an appropriate container or gas buggy. Before removing the fuel pump from the tank and to prevent contamination, clean dirt off the top of the tank.
Remove the retainer ring and lift the fuel pump out from the tank. With the fuel pump removed, inspect the interior of tank for contamination. If contaminated, have the tank cleaned or replaced to ensure the new fuel pump will not prematurely fail.
Install all accessories supplied including the replacement connector. Install the new O-ring or gasket and reinstall the retainer ring.
With the fuel tank in place and all fuel/vapor and electrical connectors in place, fill the tank with enough fuel to soak the pump and so that fuel can be drawn by the fuel pump suction port. Especially for modular units, fill the tank at least 50% as pumps are mounted higher in the module.
Install a new fuel filter to prevent excess pressure differential between the pump and filter. A dirty filter may exhibit a restriction that can reduce the pump’s life, as it will run under considerably higher pressure.
Cycle the ignition switch several times without starting the engine. This will enable the fuel delivery system to pressurize correctly and prevent long cranking time, which could be misdiagnosed as a defective pump.
Install a fuel pressure gauge and verify pressure. On return-type systems, test the fuel pressure regulator.
To ensure proper fuel pump operation, road-test the vehicle with fast accelerations and quick left and right turns.
