Deactivate the fuel system pressure, being careful not to smoke or have any source of ignition because the gasoline vapours are volatile. Unplug and disconnect the fuel supply hose of the engine fuel line assembly, and then one puts fuel system testers between the fuel hose and the fuel line assembly. Unplug the harness connector of the Auto Shutdown Relay and connect 12 volts to the terminal marked number 3 to turn on the fuel pump and pressurize the system. When the gauge displays 330 Kpa +/-14 Kpa (48 psi +/-2 psi), the pressure is correct, otherwise, record the pressure and resume testing. Disconnect jumper wire and insert the tester in the fuel line between the
Fuel Tank and the fuel filter. In case the pressure is lower than specification, repeat the 12 volts, and in case the pressure rises by 5 psi or above, change the fuel filter. In the case of no change, squeeze the return hose to verify whether there is an increase in the pressure and this will mean that the pressure regulator needs to be replaced though in the case of no change the problem could be a plugged pump filter sock or failed fuel pump. In case of pressure exceeding specification, disconnect the fuel return line hose on the chassis line at the fuel tank and connect a 3-foot length of fuel hose to a gasoline container to hold return fuel which will then undergo another pressure check. Should the pressure at this time be right, remove the kinking of the in-tank return hose and replace the fuel pump assembly in case the in-tank reservoir check valve or aspirator jet is blocked. In case of high pressure, unscrew the fuel return hose off the fuel return line and then attach a suitable hose in place of the fuel return line and insert the other end to a container to redo the pressure test, in case pressure is again high then check the fuel return line whether it is restricted or not, or replace the fuel pressure regulator otherwise it does not indicate any changes. To change the fuel pump, take out the fuel tank out of the car, remove the lock ring by ensuring that it is not tapped clockwise with a screwdriver and then ensure the assembly of the fuel pump comes out. Loosen the fuel pump in the tank to reveal the connection of the return line hose, break the connection of the fuel fitting and take the pump assembly together with the o-ring seal off. Installation requires cleaning the pump seal area of the tank followed by a new o-ring seal, install a new inlet seal and filter to the suction tube, attach the reservoir hose and press together the fittings until they fit. Fit the fuel pump in the tank, screw the locking ring clockwise and finally install the fuel tank back in the car.