Depressurize your fuel system by cranking the engine for a minimum of 15 seconds with the fuel pump fuse removed, or by using a fuel pressure gauge.
Disconnect the negative battery cable and remove fuel from fuel tank by pumping out through filler neck using suction hose. Support the fuel tank and remove fuel tank support straps. Lower fuel tank partially and remove fuel lines, electrical connectors and vent lines from tank. Remove fuel tank.
Remove any dirt that has accumulated around fuel pump attaching flange so that it will not enter fuel tank during removal and installation. Turn fuel pump locking ring counterclockwise using fuel tank sender wrench or lightly tap the locking ring evenly around. Remove the fuel pump and bracket assembly.
Remove seal gasket and discard. Do not try to reuse the seal because as soon as it hits the air, it swells and it will never seal again.
Carefully remove pump from it's mounting. Some pumps are held in with a small clamp or are placed inside a rubber mount. Unplug the wires from the fuel pump. Take note of which wires go where. Most pumps are "idiot proofed" but there are some that can be connected backwards. Also, some pumps have their wires soldered on. You will need to unsolder the old ones and solder the new ones on if this is the case.
Clean fuel pump mounting flange, fuel tank mounting surface and seal ring groove. Put a light coating oil on a new seal ring to hold it in place during assembly and install it in fuel ring groove.
Install fuel pump and sender assembly carefully to ensure that filter is not damaged. Ensure that locating keys are in keyways and seal ring remains in place. Hold assembly in place and install locking ring finger tight. Ensure that all locking tabs are under tank lock ring tabs. Secure unit with locking ring by rotating ring clockwise using fuel tank sender wrench until ring stops against stops.
Position fuel tank to vehicle and support tank while connecting fuel lines, vent line, and electrical connectors to appropriate places. Install tank in vehicle and tighten straps. Install filler tube and attaching screws. Refuel a minimum of 10 gallons of fuel and check for leaks.
Reconnect the battery ground cable then turn the ignition switch to the ON position for three seconds repeatedly (5 to 10 times) until your pressure gauge shows at least 30 psi. Check for leaks at fittings.
Remove your pressure gauge, start engine, and recheck for leaks. Start the vehicle and check for leaks while engine is running.
This is quiet a job to be taking on alone. I would suggest a helper. It usually takes at least 2 hours to do this so give yourself plenty of time so you won't have to rush and make a mistake somewhere along the way. The fuel system a vital to your vehicles performance.
Tuesday, November 4th, 2008 AT 1:33 AM