96tahoe4 door fuel pump removal. the retaining ring is sealed like its spot welded from the factory I'm questioning if the fuel pump has ever been change before.ODOMETER reading is 267000 miles.

REMOVAL & INSTALLATION


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
2. Disconnect the negative battery cable.
3. Relieve fuel system pressure using the recommended procedure.
4. Raise and safely support the vehicle.
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
6. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
7. On 1989-94 models, turn the fuel pump locking ring counterclockwise and remove the locking ring.
8. On 1995-98 models, remove 6 retaining bolts around the perimeter of the fuel pump module.
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal ring.

To install:

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
2. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
3. Install the fuel pump/sending unit assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
4. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
5. Rotate the locking ring clockwise until the ring is against the stops.
6. Install the fuel tank into the vehicle.
7. Lower the vehicle.
8. If equipped with air suspension, turn the air suspension switch to the ON position.
9. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
10. Reconnect the negative battery cable.
11. Turn the ignition switch to the RUN position several times to pressurize the fuel system. Check for fuel leaks and correct as necessary.
12. Start the engine and check for leaks.
13. Road test the vehicle and check for proper operation.

REMOVAL & INSTALLATION


CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
2. Disconnect the negative battery cable.
3. Relieve fuel system pressure using the recommended procedure.
4. Raise and safely support the vehicle.
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
6. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
7. On 1989-94 models, turn the fuel pump locking ring counterclockwise and remove the locking ring.
8. On 1995-98 models, remove 6 retaining bolts around the perimeter of the fuel pump module.
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal ring.

To install:

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
2. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
3. Install the fuel pump/sending unit assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
4. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
5. Rotate the locking ring clockwise until the ring is against the stops.
6. Install the fuel tank into the vehicle.
7. Lower the vehicle.
8. If equipped with air suspension, turn the air suspension switch to the ON position.
9. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
10. Reconnect the negative battery cable.
11. Turn the ignition switch to the RUN position several times to pressurize the fuel system. Check for fuel leaks and correct as necessary.
12. Start the engine and check for leaks.
13. Road test the vehicle and check for proper operation.

BMW has a unique habit, the automaker has, for years, used the rear passenger area of its cars to mount items like batteries, fuel pumps and fuel pump sender units. It makes sense in a weird way as it does keep wire runs short and makes access to the fuel pump and the sender unit more convenient than in other vehicles. The downside is that you have to disassemble the passenger seat to gain access to the fuel pump and the fuel pump sender.

To replace the fuel pump, you have to remove the rear seat starting with the child safety seat holddown covers. The child seat holddown covers simply unclip and slide away.

Next, you have to remove loosen the rear seat back so you can remove the rear seat bottom. The rear seat back slides up slightly so the seat bottom can be removed. You remove the rear seat bottom, being careful to watch the seatbelt lap attachment units, by moving it out and forward. It may take several movements to do this. Once the seat is free, swing it vertical and out of the way.

With the rear seat out of the way, you will see the fuel pump and fuel pump sender access cover panel. It is a sheet of composite material with four access holes per side. Remove any holddown clips or nuts that you find in the access cover panel, being careful to leave it in place, for the moment. Once you have removed the clips or nuts that are used to hold down the access cover panel , place them in a secure spot out of the way, such as an ashtray or one of the cargo trays to ensure you that the clips or nuts don't become victims of the repair (they are easily lost).

Now, it's time to orient yourself to the fuel pump and fuel sender sites. Looking toward the rear of the BMW, you will find the fuel pump on the left (passenger side) of the vehicle and the fuel pump sender unit on the right (driver side).

Next, find the access holes in the fuel pump cover seal plate. Insert a 10 mm ratchet socket and drive arm and remove the fuel pump cover plate access screws.

Since you have already loosened the fuel pump and fuel pump sender access cover panel, simply remove the sheet of composite material and expose the fuel pump cover seal plate. Now, remove the metal fuel pump cover seal plate.

On removing the fuel pump cover seal plate, you have access to the fuel pump assembly. Looking at the top of the fuel pump assembly, you will see the power plug and fuel line.

Next, remove the power plug from the left hand side of the fuel and loosen the fuel line clamp. After loosening the fuel line clamp, remove the fuel line and place it in a small metal container to trap any fuel that might leak out.

Next, remove the fuel pump retaining ring. There is a special tool available from BMW to handle this chore. Or, if you take a flat-bladed screwdriver and a small hammer and place the blade of the screwdriver against one of the raised nubs on the retaining ring, you can gently tap the screwdriver, exerting pressure toward the rear of the X5, to loosen the retaining ring. Once it is loosened, unscrew the ring by hand.

Now, remove the fuel pump assembly and place it on a cloth on the ground. The cloth is there to absorb any leakage.

Now, take the replacement fuel pump and insert it into fuel pump site and replace the retaining ring, spinning it tight by hand. Then, take the screwdriver and hammer again and gently tap the ring, exerting pressure toward the front of the vehicle.

Reattach the power lead and fuel line, tightening the fuel line clamp, and you are finished.

Clean up and complete the repair by replacing the fuel pump cover seal plate and fuel pump access cover panel. Reinsert any clips or nuts to hold down the fuel pump access cover panel. And, reinsert the four 10 mm nuts for the fuel pump cover seal plate through the access cover panel and torque them down.

Finish up by reversing the seat removal steps.

That's it, you have just finished removing and replacing the fuel pump.

SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Multi-Port Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B
Removal

1. Depressurize fuel system as outlined in Service Procedures- Fuel System Pressure Relief.
   

1. Remove rear seat cushion. Refer to Section 01-10.
   

1. Remove plastic grommet from floor pan.
   

1. Disconnect fuel pump module electrical connector.
   

1. NOTE: To disconnect fuel tubes from fuel pump module, compress tabs on both sides of each nylon push connect fitting and ease fuel tube out of fuel pump module.
   
   Disconnect fuel and vapor return tubes from fuel pump module.
   

1. Turn fuel pump locking retainer ring counterclockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent and remove fuel pump locking retainer ring.
   

1. NOTE: After fuel pump module removal, immediately cover fuel pump module opening in fuel tank in order to prevent fuel system contamination.
   
   Remove fuel pump module and cover fuel pump module opening in fuel tank.
   

1. Remove fuel pump module O-ring seal and discard.
   

Installation

1. NOTE: When cleaning fuel pump module mounting surface on fuel tank, use caution to prevent any foreign material from entering fuel system.
   
   Clean fuel pump module mounting flange and fuel pump module mounting surface and O-ring seal groove on fuel tank.
   

1. Apply a light coat of Premium Long-Life Grease XG-1-C, -K or equivalent meeting Ford specification ESA-M1C75-B on a new O-ring seal to hold it in place and install it into the O-ring seal groove on the fuel tank.
   

1. Install fuel pump module carefully to ensure that filter is not damaged. Make sure that locating keys are in keyways and O-ring seal remains in place.
   

1. Hold fuel pump module in place and install fuel pump locking retainer ring finger-tight. Make sure that all locking tabs are under fuel tank lock ring tabs.
   

1. Secure fuel pump locking retainer ring by rotating clockwise using Fuel Tank Sender Wrench D84P-9275-A or equivalent until fuel pump locking retainer ring rests against stops.
   

1. Connect fuel and vapor return tubes to fuel pump module.
   

1. Connect fuel pump module electrical connector.
   

1. Install plastic grommet in floor pan.
   

1. Install rear seat cushion. Refer to Section 01-10.
   

1. Install Multi-Port Fuel Injection (MFI) Fuel Pressure Gauge T80L-9974-B as outlined in Service Procedures-Fuel System Pressure Relief.
   

1. Turn ignition switch to RUN position for three seconds repeatedly (5 to 10 times) until pressure gauge reads at least 270 kPa (30 psi). Check for leaks at fittings.
   

1. Remove pressure gauge, start engine and recheck for leaks.
   

Hope this helps

Electric Fuel Pump REMOVAL & INSTALLATION CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on a side panel of the trunk compartment, must be turned to the OFF position before raising the vehicle.
2. Disconnect the negative battery cable.
3. Relieve fuel system pressure using the recommended procedure.
4. Raise and safely support the vehicle.
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
6. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
7. On 1988-94 models, turn the fuel pump locking ring counterclockwise and remove the locking ring.
8. On 1995-00 models, remove the retaining bolts around the perimeter of the fuel pump module.
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal ring. To install:
   
10. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
11. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install it in the seal ring groove.
12. Install the fuel pump/sending unit assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
13. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
14. Rotate the locking ring clockwise until the ring is against the stops.
15. Install the fuel tank into the vehicle.
16. Lower the vehicle.
17. If equipped with air suspension, turn the air suspension switch to the ON position.
18. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
19. Reconnect the negative battery cable.
20. Turn the ignition switch to the RUN position several times to pressurize the fuel system. Check for fuel leaks and correct as necessary.
21. Start the engine and check for leaks.
22. Road test the vehicle and check for proper operation. Fig. 1: The fuel pump is located in the fuel tank. On some models it can be viewed from the side as shown here
    Fig. 2: Electric fuel pump removal
    Fig. 3: Fuel pump locking ring installation
    

REMOVAL & INSTALLATION
CAUTION
Fuel injection systems remain under
pressure, even after the engine has been turned OFF. The fuel system pressure
must be relieved before disconnecting any fuel lines. Failure to do so may
result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on a
   side panel of the trunk compartment, must be turned to the OFF position
   before raising the vehicle.
   
2. Disconnect the negative battery cable.
   
3. Relieve fuel system pressure using the recommended procedure.
   
4. Raise and safely support the vehicle.
   
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
   
6. Remove any dirt that has accumulated around the fuel pump retaining flange
   so it will not enter the tank during pump removal and installation.
   
7. On 1988-94 models, turn the fuel pump locking ring counterclockwise and
   remove the locking ring.
   
8. On 1995-00 models, remove the retaining bolts around the perimeter of the
   fuel pump module.
   
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal
   ring.
   To install:
   
   
10. Clean the fuel pump mounting flange, fuel tank mounting surface and seal
    ring groove.
    
11. Apply a light coating of grease on a new seal ring to hold it in place
    during assembly and install it in the seal ring groove.
    
12. Install the fuel pump/sending unit assembly carefully to ensure the filter
    is not damaged. Make sure the locating keys are in the keyways and the seal ring
    remains in the groove.
    
13. Hold the pump assembly in place and install the locking ring finger-tight.
    Make sure all the locking tabs are under the tank lock ring tabs.
    
14. Rotate the locking ring clockwise until the ring is against the stops.
    
15. Install the fuel tank into the vehicle.
    
16. Lower the vehicle.
    
17. If equipped with air suspension, turn the air suspension switch to the
    ON position.
    
18. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
    
19. Reconnect the negative battery cable.
    
20. Turn the ignition switch to the RUN position several times to
    pressurize the fuel system. Check for fuel leaks and correct as necessary.
    
21. Start the engine and check for leaks.
    
22. Road test the vehicle and check for proper operation.
    
    
    
    
    
    Fig. 1: The fuel pump is located in the fuel tank. On some
    models it can be viewed from the side as shown here
    
    
    
    
    
    
    
    Fig. 2: Electric fuel pump removal
    
    
    
    
    
    
    
    Fig. 3: Fuel pump locking ring installation
    
    

Electric Fuel Pump REMOVAL & INSTALLATION Non-Supercharged

1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
2. Remove the fuel tank and place it on a bench.
3. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
4. Turn the fuel pump locking ring counterclockwise and remove the locking ring.
5. Remove the fuel pump and bracket assembly. Remove and discard the seal ring. To install:
   
6. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
7. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
8. Install the fuel pump and bracket assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
9. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
10. Rotate the locking ring clockwise until the ring is against the stops.
11. Install the fuel tank in the vehicle. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
12. Install a suitable fuel pressure gauge on the valve on the fuel rail.
13. Turn the ignition switch from OFF to ON for 3 seconds. Repeat this procedure 5–10 times until the pressure gauge shows at least 35 psi. Check for fuel leaks.
14. Remove the pressure gauge, start the engine and check for leaks.

REMOVAL & INSTALLATION NOTE: On CIS systems the main fuel pump is located under the vehicle in front of the rear axle or in front of the tank on the right side. 1990–92 Cabriolet, Golf, Jetta and Fox TRANSFER PUMP

1. Remove the rear seat and the access cover.
2. Disconnect the wiring and hoses and unscrew the lock ring.
3. Carefully lift out the pump and gauge sending unit assembly.
4. When installing the assembly, use a new seal.

MAIN PUMP

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Raise and safely support the rear or right side of the vehicle on jack stands.
4. Disconnect the wiring from the pump. Clean any dirt away from the fuel line fitting.
5. Use locking pliers to pinch off the fuel line from the transfer pump to the main pump. If the fuel line is metal, remove the rear seat and access panel and disconnect the line at the transfer pump.
6. Place a pan under the pump and disconnect the fuel line fitting from the pump.
7. Remove the retaining ring screws and slide the pump out of the reservoir. To install:
   
8. Moisten the pump O-ring with a little fuel and slide it into the reservoir. Install the retaining ring screws.
9. When connecting the fittings, use new copper washers and tighten the fittings to 15 ft. lbs. (20 Nm).

1993–99 Cabrio, Golf, and Jetta

1. Remove the negative battery cable.
2. Raise and safely support the vehicle.
3. Relieve the fuel system pressure.
4. Remove the rear seat and the access cover.
5. Disconnect the wiring and hoses.
6. Remove the fuel lines from the pump.
7. On 1993–99 Golf, Jetta and Cabrio vehicles, unscrew the fuel pump retaining ring.
8. On all other models, remove the mounting bolts and the fuel pump.
9. Carefully lift out the pump and gauge sending unit assembly.
10. Empty the fuel pump into an approved container. To install:
    
11. Installation is the reverse of removal. Be sure to use new sealing rings and/or gaskets.

Ford Crown Victoria/Grand Marquis 1989-1998

Electric Fuel Pump - REMOVAL & INSTALLATION

CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFF position before raising the vehicle.
2. Disconnect the negative battery cable.
3. Relieve fuel system pressure using the recommended procedure.
4. Raise and safely support the vehicle.
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
6. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
7. On 1989-94 models, turn the fuel pump locking ring counterclockwise and remove the locking ring.
8. On 1995-98 models, remove 6 retaining bolts around the perimeter of the fuel pump module.
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal ring.
   

To install:

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
2. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install in the seal ring groove.
3. Install the fuel pump/sending unit assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
4. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
5. Rotate the locking ring clockwise until the ring is against the stops.
6. Install the fuel tank into the vehicle.
7. Lower the vehicle.
8. If equipped with air suspension, turn the air suspension switch to the ON position.
9. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
10. Reconnect the negative battery cable.
11. Turn the ignition switch to the RUN position several times to pressurize the fuel system. Check for fuel leaks and correct as necessary.
12. Start the engine and check for leaks.
13. Road test the vehicle and check for proper operation.
    

See Figures 1, 2 and 3




Fig. 1: The fuel pump is located in the fuel tank. On some models it can be viewed from the side as shown here



Fig. 2: Electric fuel pump removal



Fig. 3: Fuel pump locking ring installation


Hope this hel to solve your problem (remembercomment and rated this).

Removal & Installation See fuel pump under fuel tank in this section.

CAUTION Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. If equipped with air suspension, the air suspension switch, located on a side panel of the trunk compartment, must be turned to the OFF position before raising the vehicle.
   
2. Disconnect the negative battery cable.
   
3. Relieve fuel system pressure using the recommended procedure.
   
4. Raise and safely support the vehicle.
   
5. Remove the fuel tank from the vehicle and place on a suitable work bench.
   
6. Remove any dirt that has accumulated around the fuel pump retaining flange so it will not enter the tank during pump removal and installation.
   
7. On 1988–94 models, turn the fuel pump locking ring counterclockwise and remove the locking ring.
   
8. On 1995–00 models, remove the retaining bolts around the perimeter of the fuel pump module.
   
9. Remove the fuel pump/sending unit assembly. Remove and discard the seal ring.
   

To install:

1. Clean the fuel pump mounting flange, fuel tank mounting surface and seal ring groove.
   
2. Apply a light coating of grease on a new seal ring to hold it in place during assembly and install it in the seal ring groove.
   
3. Install the fuel pump/sending unit assembly carefully to ensure the filter is not damaged. Make sure the locating keys are in the keyways and the seal ring remains in the groove.
   
4. Hold the pump assembly in place and install the locking ring finger-tight. Make sure all the locking tabs are under the tank lock ring tabs.
   
5. Rotate the locking ring clockwise until the ring is against the stops.
   
6. Install the fuel tank into the vehicle.
   
7. Lower the vehicle.
   
8. If equipped with air suspension, turn the air suspension switch to the ON position.
   
9. Add a minimum of 10 gallons of fuel to the tank and check for leaks.
   
10. Reconnect the negative battery cable.
    
11. Turn the ignition switch to the RUN position several times to pressurize the fuel system. Check for fuel leaks and correct as necessary.
    
12. Start the engine and check for leaks.
    
13. Road test the vehicle and check for proper operation.
    

The fuel pump is located in the fuel tank. On some models it can be viewed from the side as shown here


Electric fuel pump removal


Fuel pump locking ring installation