Will my mechanical fuel pump work if I disconnect the power to my in-tank electric fuel pump? Can I remove my return line and vapor line?

1. Properly relieve the fuel system pressure and install a pressure test gauge according to the tool manufacturers instructions.
   
2. Turn the ignition switch to the ON position for 3 seconds, then turn to the OFF position for 5 seconds. Repeat this procedure two or three times to pressurize the system. Again turn the switch to the ON position.
   
   1. On TBI equipped vehicles, the gauge should read a static pressure of between 9 and 13 psi (62-89kPa)
      
   2. On SFI equipped vehicles, the gauge should read a static pressure of between 41 and 47 psi (248-325kPa)
      
   3. If not, check for a clogged fuel filter, a kinked fuel line, or an inoperative fuel pump.
      
3. On TBI equipped vehicles, the fuel pressure will drop after the fuel pump stops running due to a controlled bleed in the fuel system. Use of the fuel pressure gauge will determine if the fuel system pressure is enough for the engine to start and run.
   
4. No fuel spray from the injector indicates a faulty fuel or ignition system or no PCM control of the injector.
   
5. This test will determine if the ignition control module is not generating the reference pulse or if the wiring or PCM are at fault. By touching and removing a test light to B+ on CKT 430 (purple/white wire from the ignition system), a reference pulse should be generated. If the injector test light blinks, the PCM and wiring are OK.
   

If the pump tests bad...
Disconnect the negative battery cable.

1. Relieve the fuel system pressure.
   
2. Block the front wheels and raise and support the rear of the vehicle safely. Make sure the rear is high enough to accommodate the removal of the fuel cell.
   
3. Loosen the fuel filler neck connecting tube clamp at the tank.
   
4. Wrap a shop towel around the fuel filter neck connecting tube and slowly remove the fuel filler neck connecting tube from the fuel tank.
   
5. Position a siphon hose into the fuel tank through the fuel filler opening. Place the other end into an approved container with enough capacity to hold the fuel in the tank. Siphon the fuel.
   
6. Raise the vehicle to gain access to the fuel tank. Make sure the vehicle is safely supported.
   

1. Disconnect the tail pipe hanger attaching bolt.
   
2. Remove the muffler hanger attaching bolts and remove the muffler hanger.
   
3. Loosen the converter hanger attaching nuts.
   
4. Remove the two heat shield attaching screws and note the position for reassembly.
   
5. Support the exhaust and move the heat shield to gain the access to the right side of the fuel tank retaining strap attaching bolts.
   
6. Remove the in-line fuel filter body clips.
   

If the nylon fuel feed or return lines becomes kinked, and cannot be straightened, they must be replaced. Do not attempt to repair sections of the nylon fuel lines.

1. Disconnect the quick-connect fitting at the fuel filter, and return line fitting.
   
2. Disconnect the fuel tank electrical connector.
   
3. Disconnect the vapor hose at the fuel tank.
   
4. Disconnect the vent hose at the fuel tank.
   

With the aid of an assistant, support the fuel tank, remove the left and right tank retaining strap attaching bolts, and remove the tank.

1. As necessary, remove the fuel sending unit (which includes the fuel pump), as outlined, in this section.
   
2. Then you can change the pump:
   
3. Remove the fuel sender assembly.
   
4. Disassemble the fuel pump strainer and the fuel pump: Note the position of the strainer in relation to the pump.
   
5. See Figure 3
   
   
   Fig. 3: Remove the fuel tank locking ring with a non-sparking (brass) punch.
   
   
   
   1. Support the fuel pump in one hand, and grab the strainer in the other hand.
      
      1. Rotate strainer in one direction and pull off pump. Discard strainer.
         
   
   
   
   
   
   
   1. 1. Remove deflector.
         
   1. Disconnect the fuel pump electrical connector.
      
   2. Loosen the two connecting clamps, if equipped.
      
   3. Place the fuel sender assembly upside down on the work bench.
      
      1. Pull the fuel pump downward to remove it from the mounting bracket, then tilt the pump outward and remove it from the connecting hose or the fuel pulse dampener.
         
   4. It is recommended to replace the hose and clamps, if equipped.
      
   To install:
   
   1. Push the fuel pump assembly into the attaching hose. Attach the pump electrical wires and fasten the hose clamps to the attaching hose and around the pump body, where equipped.
      
   2. Place the fuel tank sender and pump assembly into the fuel tank. Use a new O-ring seal during assembly.
      
   3. Then put the tank back in:
      
   4. 1. If the fuel tank is replaced, transfer the fuel feed and return lines from the mounting clips, the vapor hose from the mounting clips and the vent hose from the vent hose fitting.
         
      2. Check the fuel filler neck for cracks and holes and replace as necessary.
         
      3. Install the fuel sending unit.
         
      4. With the aid of an assistant, position and support the fuel tank and install the left and right tank retaining strap attaching bolts and tighten to 18 ft. lbs.
         
      5. Connect the vent and vapor hoses.
         
      6. Connect the fuel sending unit electrical connector.
         
      7. Connect the quick-connect fittings as outlined.
         
      8. Position the fuel sending unit electrical connector and fuel return line under the in-line fuel filter bracket.
         
      9. Install the in-line fuel filter and new body clips.
         
      10. Reposition the heat shield as noted during removal and tighten the retaining screws to 18 lbs. ft.
          
      11. Tighten the converter hanger attaching bolts to 20 lbs. ft.
          
      12. Install the muffler hanger and attaching bolts and tighten to 18 lbs. ft.
          
      13. Install the tailpipe hanger attaching bolt and tighten to 20 lbs. ft.
          
      14. Lower the vehicle, add fuel and install the fuel filler cap.
          
      15. Connect the negative battery cable.
          
      16. Turn the ignition switch to the ON position for 3 seconds, then turn to the OFF position for 5 seconds. Repeat this procedure two or three times to pressurize the system. Again turn the switch to the ON position and check for leaks.
          

Fuel Pump REMOVAL & INSTALLATION 1.9L Engine To prevent excessive fuel spillage, whenever the tank is removed from the vehicle it should be no more than 1?2 full. Removal of the fuel pump module assembly requires the removal of the fuel tank.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Fuel feed and return lines from the filter/pressure regulator
   • Fuel pump vapor line from the fuel tank vent pipe
   • Fuel pump module retaining ring with service tool SA9156E. A 1?2 inch breaker bar will loosen the lockring
   NOTE: To prevent bending of the sending unit float arm, lift the pump module up slightly to disengage the orientation tabs in the tank. Rotate the module 90 degrees clockwise until the fuel lines are facing the 1 o'clock position.
   • Fuel pump module from the fuel tank until the bottom of the pump module is close to the fuel tank opening
   • Tilt the pump module approximately 45 degrees to the right hand side of the tank and lift the pump from the fuel tank
   • Fuel pump to tank seal and discard it
   To install:
   
4. Install or connect the following:
   • Fuel pump module into the fuel tank by orientating the float to face the right side and tilting the module approximately 45 degrees
   • Fuel pump into the tank and rotate the assembly 90 degrees counterclockwise to align the module tabs with the slots in the tank
   NOTE: The fuel pump retaining ring cannot be properly installed if the flange locator tabs are not aligned with the slots in the fuel tank.
   • Retaining lockring with tool SA9156E
   • Vapor line to the fuel tank vent pipe
   • Fuel feed and return lines to the filter/pressure regulator
   • Fuel feed, return and EVAP canister purge line in the fuel tank retaining clip
   • Fuel tank
   • Negative battery cable
5. Start the vehicle and check for leaks, repair if necessary.

2.2L and 3.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Fuel tank
   • Fuel lines from the fuel pump module cover
   • Fuel pump module retaining ring with a Sending Unit Wrench, J43827
   • Pull the retaining clip toward the float arm and lift up
   • Fuel pump straight up from the fuel tank
   • Fuel pump tank seal and discard the seal
   • Fuel feed line from the bottom of the fuel pump cover with Clamp Pliers J43914
   • Fuel pump electrical connector Fig. 1: Remove the fuel pump cover lockring-2.2L and 3.0L engines
     
   To install:
   
4. Install or connect the following:
   • Fuel pump feed line to the cover
   • Fuel pump electrical connector
   • Fuel pump to the new seal
   • Fuel pump cover lockring with tool J-43827
   • Fuel lines and wiring harness
   • Fuel tank
   • Negative battery cable
5. Start the vehicle and check for leaks, repair if necessary.

It's inside the fuel tank. Access is on top. Remove tank. 2 straps hold it in place.

Removal

1. Relieve fuel system pressure as described under Fuel System Pressure Relief.
   

1. Drain fuel from the fuel tank as described.
   

1. Raise vehicle on hoist.
   

1. Remove the exhaust system as required. Refer to Section 09-00.
   

1. NOTE: The connections for the rear fuel supply return and vapor tube (9S278) to the fuel pump module are on top of the fuel tank and are inaccessible. They must be disconnected with the fuel tank partially lowered from the vehicle.
   
   Disconnect fuel tank to filler pipe hose (9047) and vent hoses connecting the fuel tank filler pipe (9034) to fuel tank. Disconnect one end of the vapor crossover hose at the rear over the driveshaft (4602).
   

1. Place a safety support under the fuel tank. Remove the bolts from the fuel tank support straps (9092). Take care not to deform the fuel tank or fuel tank support straps. Fuel tank capacity and/or fuel pick-up may be adversely affected.
   

1. Partially remove the fuel tank and disconnect the rear fuel supply return and vapor tubes at push connect fittings using Fuel Line Disconnect Tool Set T90T-9550-S. Disconnect electrical connector from the fuel pump module.
   

1. Remove fuel tank from the vehicle.
   

Tank Assembly REMOVAL & INSTALLATION CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury. 1988 Vehicles Fig. 1: Fuel tank mounting components
Fig. 2: Fuel tank insulator mounting positions

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure, as outlined earlier in this section.
3. Raise and safely support the vehicle.
4. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container. CAUTION
   Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.
   
5. Support the fuel tank with a suitable jack.
6. Remove the 2 bolts securing the fuel tank straps, then swing the straps out of the way.
7. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
8. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips. If equipped, disconnect the ground strap.
9. Disconnect the fuel filler and vent hoses from the fuel tank.
10. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected. To install:
    
11. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
12. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
13. Connect the fuel feed and return lines to the sender assembly.
14. Attach the electrical connector to the fuel sender assembly. If equipped, connect the ground strap.
15. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
16. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
17. Remove the jack.
18. Connect the fuel filler and vent hoses to the tank.
19. Carefully lower the vehicle, then refill the fuel system
20. Connect the negative battery cable, then install the fuel filler cap, if not done already.
21. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.

1989–94 Vehicles

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure, as outlined earlier in this section.
3. Raise and safely support the vehicle. CAUTION
   Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.
   
4. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container. NOTE: Before disconnecting any fuel lines from the fuel tank, thoroughly clean around all hose connections.
   
5. Disconnect the fuel filler vent hose from the fuel tank.
6. Detach the fuel filler hose from the fuel filler inlet tube on the fuel tank. Position the hose out of the way.
7. Disconnect the vapor hose from the front of the fuel tank.
8. Detach the fuel return pipe and position the hose out of the way.
9. Disconnect the two rear rubber exhaust hangers from the rear of the exhaust system and allow the exhaust system to hang down slightly.
10. Unfasten the exhaust shield mounting bolts, then remove the exhaust shield.
11. Support the fuel tank with a suitable jack.
12. Remove the two bolts securing the fuel tank straps, then swing the straps out of the way.
13. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
14. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips.
15. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected. To install:
    
16. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
17. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
18. Connect the vapor hose to the fuel tank at the vapor pipe at the rear of the tank and connect the vapor hose to the sender assembly.
19. Attach the electrical connector to the fuel sender assembly.
20. Connect the fuel feed and return lines to the sender assembly.
21. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
22. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
23. Remove the jack.
24. Connect the fuel return pipe to the fuel feed pipe.
25. Attach the rear fuel feed pipe to the inlet side of the fuel filter.
26. Tighten the line fittings to 16 ft. lbs. (22 Nm). Make sure to use a back-up wrench to prevent the fuel filter from turning.
27. Connect the vapor hose to the vapor pipe at the front of the vehicle.
28. Attach the fuel filler vent hose to the tank. Connect the fuel filler hose to the fuel filler neck of the tank.
29. Install the exhaust heat shield and the mounting bolts.
30. Position the exhaust system and install the rubber hangers.
31. Carefully lower the vehicle, then refill the fuel system
32. Connect the negative battery cable, then install the fuel filler cap, if not done already.
33. Turn the ignition switch ON for 2 seconds, OFF for 10 seconds, then ON and check for fuel leaks.

The fuel pressure regulator is built in to the fuel pump


Fuel tank and fuel pump assembly—XG 300

1. Before servicing the vehicle, refer to the Precautions section.
   
2. Relieve the fuel system pressure.
   
3. Drain the fuel tank.
   
4. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Fuel supply, return and vapor lines
     
   • Fuel fill and vent hoses
     
   • Fuel pump module connector
     
   • Fuel level sender connector
     
   • Fuel tank straps
     
   • Fuel tank
     
   • Fuel pump module
     

To install:

1. Install or connect the following:
   
   • Fuel pump module and torque the mounting bolts to 12–24 inch lbs. (1–3 Nm)
     
   • Fuel tank
     
   • Fuel tank straps
     
   • Fuel level sender connector
     
   • Fuel pump module connector
     
   • Fuel fill and vent hoses
     
   • Fuel supply, return and vapor lines
     
   • Negative battery cable
     
2. Fill the tank with fuel and check for proper fuel pump operation.
   

STEPS TO CHANGE FUEL PUMP

1. Park the vehicle in a safe place and make sure there is enough room around the back of the vehicle for you to work and move tools around.
2. Start the engine and let it idle while you relieve the fuel system pressure by removing the fuel pump fuse or relay from the fuse box. Wait a few seconds for the engine to stall, turn the ignition key off and replace the relay or fuse.
3. Raise the back of your car using a floor jack and support it safely on jack stands.
4. Disconnect the fuel tank filler pipe and the fuel pump connector located above the cross member underneath the vehicle.
5. Disconnect the vapor tube from the tee connector on the right side of the car-passenger side-and the vapor line from the canister tube.
6. Support the fuel tank with a jack and remove the nuts from the holding strap using a wrench or ratchet and socket. Move the strap away and lower the fuel tank. Discard the fuel tank mounting studs.
7. Unplug the pressure transducer electrical connector located on the top rear corner of the fuel tank.
8. Clean the area around the fuel pump mounting flange and remove the flange mounting bolts in a crisscross pattern.
9. Lift the fuel pump assembly off the tank. Replace the new fuel pump in the assembly and install the assembly in the tank. Install the flange screws and torque to 89 inch lbs. (10Nm) using a crisscross pattern.
10. Raise the fuel tank to its mounting position, install the strap using new mounting studs and torque the nuts to 26 foot lbs. (35 Nm).
11. Connect the fuel pressure transducer electrical connector, vapor tube to the tee connector, vapor line to the canister tube, fuel tank filler pipe and fuel pump electrical connector.
12. Lower the vehicle, start the engine and check for leaks.

REMOVAL

1. Relieve fuel system pressure.
2. Disconnect battery ground cable.
3. Remove fuel filler door.
4. Remove fuel cap.
5. Remove fuel tank filler neck housing and disconnect drain hose.
6. Remove screws attaching fuel meter/fuel pump to tank.
7. Disconnect fuel lines, fuel vapor line and electrical connector.
8. Remove fuel meter/fuel pump and gasket.
9. Replace fuel pump.

INSTALLATION

1. Reverse procedure to install.

Removal & Installation To Remove:

1. Properly relieve the fuel system pressure.
2. Drain the fuel tank through the filler pipe.
3. Support the fuel tank.
4. Remove or disconnect the following:
   • Negative battery cable
   • Filler neck
   • Shield and tank straps
   • Fuel lines and vapor hose from pump and tank
   • Electrical connection from fuel pump
   • Fuel tank
   • Fuel pump/sending unit assembly by turning the locking ring (located on top of the fuel tank) counterclockwise using a spanner wrench
   • Fuel pump from the fuel lever sending device

To Install:

1. Install or connect the following:
   • Fuel pump in tank with new seal around opening
   • Tank and connect fuel lines and vapor hose
   • Tank to the frame
     1. Torque to: 33 ft. lbs. (45 Nm)
   • Shield
   • Fuel filler neck and clamp
   • Negative battery cable
2. Refill the tank.
3. Run the engine and check for leaks.

Hi, this will help you achieve your goal.


Step 1

Park the vehicle in a safe place and make sure there is enough room around the back of the vehicle for you to work and move tools around.

Step 2

Start the engine and let it idle while you relieve the fuel system pressure by removing the fuel pump fuse or relay from the fuse box. Wait a few seconds for the engine to stall, turn the ignition key off and replace the relay or fuse.

Step 3

Raise the back of your car using a floor jack and support it safely on jack stands.

Step 4

Disconnect the fuel tank filler pipe and the fuel pump connector located above the cross member underneath the vehicle.

Step 5

Disconnect the vapor tube from the tee connector on the right side of the car-passenger side-and the vapor line from the canister tube.

Step 6

Support the fuel tank with a jack and remove the nuts from the holding strap using a wrench or ratchet and socket. Move the strap away and lower the fuel tank. Discard the fuel tank mounting studs.

Step 7

Unplug the pressure transducer electrical connector located on the top rear corner of the fuel tank.

Step 8

Clean the area around the fuel pump mounting flange and remove the flange mounting bolts in a crisscross pattern.

Step 9

Lift the fuel pump assembly off the tank. Replace the new fuel pump in the assembly and install the assembly in the tank. Install the flange screws and torque to 89 inch lbs. (10Nm) using a crisscross pattern.

Step 10

Raise the fuel tank to its mounting position, install the strap using new mounting studs and torque the nuts to 26 foot lbs. (35 Nm).

Step 11

Connect the fuel pressure transducer electrical connector, vapor tube to the tee connector, vapor line to the canister tube, fuel tank filler pipe and fuel pump electrical connector.

Step 12

Lower the vehicle, start the engine and check for leaks.

http://www.autozone.com/shopping/repairGuide.htm?pageId=0900c152801dbaf3

when you drop the tank by following these directions you will have access to the pump

1989-94 Vehicles
See Figures 1 and 2

1. Disconnect the negative battery cable.
2. Properly relieve the fuel system pressure, as outlined earlier in this section.
3. Raise and safely support the vehicle.

CAUTION Observe all applicable safety precautions when working around gasoline. Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical (Class B) fire extinguisher near the work area. Never drain or store fuel in an open container due to the possibility of fire or explosion.

1. Use a suitable hand operated pump device to drain the fuel through the filler tube into an approved container.

Before disconnecting any fuel lines from the fuel tank, thoroughly clean around all hose connections.

1. Disconnect the fuel filler vent hose from the fuel tank.
2. Detach the fuel filler hose from the fuel filler inlet tube on the fuel tank. Position the hose out of the way.
3. Disconnect the vapor hose from the front of the fuel tank.
4. Detach the fuel return pipe and position the hose out of the way.
5. Disconnect the two rear rubber exhaust hangers from the rear of the exhaust system and allow the exhaust system to hang down slightly.
6. Unfasten the exhaust shield mounting bolts, then remove the exhaust shield.
7. Support the fuel tank with a suitable jack.
8. Remove the two bolts securing the fuel tank straps, then swing the straps out of the way.
9. Lower the fuel tank enough to disconnect the vapor hose from the fuel sender assembly and the vapor hose from the vapor pipe at the rear of the fuel tank.
10. Detach the electrical connector from the fuel sender assembly and remove the two retaining clips.
11. Remove the tank from the vehicle, slowly to ensure all connections and hoses have been disconnected.

To install:

1. Clean all parts well. Inspect the tank for dents, rust or other damage. On high-mileage vehicles, it may be good practice to remove the fuel pump module and replace the flexible strainer on the fuel pump.
2. Position the fuel tank under the vehicle and raise the tank with a suitable jack.
3. Connect the vapor hose to the fuel tank at the vapor pipe at the rear of the tank and connect the vapor hose to the sender assembly.
4. Attach the electrical connector to the fuel sender assembly.
5. Connect the fuel feed and return lines to the sender assembly.
6. Raise the tank into position into the vehicle and swing the mounting straps under the tank.
7. Install the front fuel tank strap mounting bolts and tighten to 35 ft. lbs. (47 Nm).
8. Remove the jack.
9. Connect the fuel return pipe to the fuel feed pipe.
10. Attach the rear fuel feed pipe to the inlet side of the fuel filter.
11. Tighten the line fittings to 16 ft. lbs. (22 Nm). Make sure to use a back-up wrench to prevent the fuel filter from turning.
12. Connect the vapor hose to the vapor pipe at the front of the vehicle.
13. Attach the fuel filler vent hose to the tank. Connect the fuel filler hose to the fuel filler neck of the tank.
14. Install the exhaust heat shield and the mounting bolts.
15. Position the exhaust system and install the rubber hangers.
16. Carefully lower the vehicle, then refill the fuel system
17. Connect the negative battery cable, then install the fuel filler cap, if not done already.
18. Turn the ignition switchONfor 2 seconds, OFF for 10 seconds, thenONand check for fuel leaks.