- 1). Relieve the fuel system's pressure by disconnecting the fuel pump relay from the fuse box; opening the gas cap will also help. Start the engine and let it run until it stalls. Disconnect the negative battery cable and siphon the fuel out of the tank.
- 2). Remove the fuel tank. Unscrew and remove the flange with the fuel door and raise the truck on jack stands. Remove the shield covering the tank and the "EVAP" canister, then disconnect the fuel supply lines. Raise a transmission jack under the tank, then unbolt and remove the tank's straps. Lower the jack and disconnect the electrical connectors, fuel lines and "EVAP" line from the fuel pump module and the filler hose from the tank.
- 3). Release the retaining ring's locking tab with a pointed tool, grip the ring with a set of locking pliers and rotate the ring counterclockwise to loosen it. Pull the fuel pump module out of the tank, tilting it slightly at an angle.
- 4). Clean the surface of the tank with acetone or lacquer thinner. Install a new seal on the replacement pump module.
- 5). Insert the new fuel pump module into the tank, aligning it so the fuel line connections will reach the fuel lines. Press the module down until it is seated and then install the retaining ring, making sure it is properly seated and the locking tap is in place within the slot.
- 6). Connect the fuel and EVAP lines to the pump assembly. Install the tank back on the truck in reverse order of removal.
- 7). Re-pressurize the fuel system. Reconnect the fuel pump relay battery cable. Turn the engine to the "on" position for two seconds and then back off for five. Repeat this up to 10 times.
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