Service Manual

4.25
ELECTRONIC FUEL INJECTION
4
Fuel Pump Removal / Installation
1. Remove the (6) mounting screws and carefully remove the
fuel pump from the tank. Take care not to damage the fuel
sender float or fuel pick-up screen.
2. Replace O-ring on fuel pump assembly.
3. Clean the tank’s mating surface with Isopropyl Alcohol.
4. Carefully install the fuel pump into the tank. Take care not
to damage the fuel sender float or fuel pick-up screen.
5. Install and hand tighten the mounting screws.
6. Torque screws to specification following the sequence
show in the illustration below.
7. Apply the final torque using the same sequence.
Fuel Tank Installation
1. Carefully reinstall the fuel tank assembly.
2. Reinstall the (2) tank brackets and fasteners.
3. Reinstall the rear RH fender well and secure with fasteners.
4. Reinstall the seat belt mechanism and secure the lower bolt.
5. Reinstall the RH rocker panel and all (15) fasteners.
6. Reinstall the rear seat base and secure with the (2) fasteners.
7. Reinstall the push rivets into the rear of the center console.
8. Install the fuel line and vent hose and verify they are secure.
9. Reconnect the fuel pump electrical harness.
10. Reconnect the negative battery cable. Test the fuel pump
by turning on the key and listening for the pump to activate.
11. Finally, install the rear service panel along with the driver
and passenger seats.
FUEL PRESSURE REGULATOR
Operation Overview
The fuel pressure regulator maintains the required operating
system pressure of 39 psi + 3psi. A rubber-fiber diaphragm
divides the regulator into two separate sections; the fuel
chamber and the pressure regulating chamber. The pressure
regulating spring presses against the valve holder (part of the
diaphragm), pressing the valve against the valve seat. The
combination of atmospheric pressure and regulating spring
tension equals the desired operating pressure. Any time the fuel
pressure against the bottom of the diaphragm exceeds the
desired (top) pressure, the valve opens, relieving the excess
pressure, returning the excess fuel back to the tank.
Fuel Pressure Regulator Test
Refer to the “Fuel Pump Test” procedure.
See “Fuel Pump Test” on page 4.21.
Fuel Pressure Regulator Replacement
The pressure regulator is a sealed, non-serviceable assembly. If
it is faulty, the fuel pump assembly must be replaced. Refer to
the “Fuel Pump Removal / Installation” procedure.
NOTE: See the “Electronic Parts Catalog” for fuel
pump availability. It may be possible that the fuel
tank assembly must be replaced.
WARNING
Never reuse the O-ring
= T
Fuel Pump Mounting Screw Torque:
1st Sequence: 10-14 in. lbs. (1.1-1.6 Nm)
Final Sequence: 25-28 in. lbs. (2.8-3.2 Nm)
Remove (6)
mounting Screws