4.33
Fuel Systems
4
8. Remove the fuel tank from the chassis.
9. Place the fuel tank is a well-ventilated area.
10. Remove and discard the six fuel pump flange screws.
11. Carefully extract the fuel pump assembly out of the tank.
12. Discard the fuel pump flange gasket. If the pump has failed,
discard the fuel pump. If the fuel tank is to be replaced,
obtain the new fuel tank.
13. Saturate a clean rag with isopropyl alcohol and clean the
surface of the fuel pump flange area, and the fuel pump
flange. Dry all surfaces with a clean rag. Allow adequate
drying time for the alcohol.
14. Install a new, clean gasket by carefully sliding it over the
fuel lines, and pump components. Position the gasket with
the barbs/locating pins facing the flange. Align the pins/
barbs with the holes, then push and pull the barbs/pins
through the holes in the flange.
15. Carefully slide the pump assembly into the fuel tank until
the gasket rests on the tank.
16. Using new screws, supplied with the new gasket, thread in
one of the top two screws to locate the gasket and flange in
the fuel tank. A few turns of the screw is sufficient.
17. Thread the remaining five screws in by hand.
18. Using a nut driver or socket and following the specified
torque sequence, sequentially turn each screw a few
revolutions at a time until the gasket is just seated between
the flange and the fuel tank.
19. Using a torque wrench and the specified torque sequence,
tighten all screws to 10 in.lbs. (1.13 Nm). Tighten each
screw in one continuous, quick motion.
20. After completing the initial torque sequence, tighten each
screw to 23 in.lbs. (2.6 Nm) in one continuous, quick
motion.
21. After installing the fuel pump assembly, the fuel tank must
be tested for leaks by pressurizing the tank.See “Fuel Tank
Pressure Test” on page 4.30.
CAUTION
NEVER RE-USE THE FUEL PUMP FLANGE GASKET.
ALWAYS INSTALL FUEL PUMP USING A NEW
FALNGE GASKET.
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