General
The fuel pump pumps fuel from the tank sump and provides filtered, pressurized fuel to the fuel rail. The fuel rail pressure is controlled by a pressure regulator. The injectors receive fuel directly from the fuel rail. The bypass fuel from the pressure regulator is returned to the tank sump via the external fuel return line.
Note. Before removing the fuel pump, perform appropriate diagnostics listed in the VRSCA Electrical Diagnostic Manual (Part No. 99499-02).
Removal
1. See Figure 4-5. Remove the black and red wire leads from the fuel pump (5).
Figure 4-5. Fuel pump/filters/fuel level sender assembly: 1. Sending unit; 2. Pressure side filter; 3. Bracket; 4. Suction side filter; 5. Fuel pump; 6. Crossover hose; 7. Support rod
2. Pull the suction side filter off of the inlet port. The retaining ring will remain on the fuel pump.
3. Cut clamp holding crossover hose (6) to pressure side filter and pull the fuel crossover hose off the pressure side filter.
4. Rush the fuel pump up and out of its bracket (3).
5. Inspect all fuel pump and fuel level sending unit (1) wiring.
Caution! Carefully inspect hoses for cuts, tears, holes or other damage. Replace hose if any damage is found. Even the smallest hole can cause a reduction in fuel pressure.
Installation
| PART NO. | SPECIALTY TOOL |
| HD-41137 | Hose clamp pliers |
1. See Figure 4-5. Push a new fuel pump (5) down into its bracket (3) against the screwed on bracket stop.
2. Route new crossover hose (6) on the side of the support rod (7) opposite the fuel level sender float.
3. Install new clamps over new crossover hose (6) and attach to the pressure side filter using side of HOSE CLAMP PLIERS (HD-41137).
4. If required, replace fuel pump wiring or fuel level sender wiring.
Caution! Do not replace the special teflon coated fuel pump wiring with ordinary bulk wire. Ordinary insulation materials may deteriorate when in contact with gasoline.
5. Press the black and red wire leads onto the clips.
6. Press a new suction side filter (4) onto the strainer inlet at the bottom of the fuel pump (5).
7. Install fuel pump/filters/fuel level sender assembly into gas tank. See 4.2 Fuel pump/filters/fuel level sender assembly.
8. After installation of fuel pump/filters/fuel level sender assembly, verify fuel pump operation with a fuel system pressure test. See 9.10 Fuel pressure test.