Fuel Pump: Service and Repair

Fuel Sender/Pump Assembly In Fuel Tank.:

REMOVAL

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Drain the fuel tank, refer to MAINTENANCE PROCEDURES/DRAINING THE FUEL TANK.
4. Remove the fuel tank and fuel level sender assembly, refer to FUEL TANK AND FUEL LEVEL SENDER ASSEMBLY.
5. Note the position of the fuel pump strainer on the fuel pump.
6. Support the pump with one hand and grasp the strainer with the other hand.
- Rotate the strainer in one direction and pull it off of the pump. Discard the strainer.
7. Disconnect the fuel pump electrical connector.
8. Loosen the pulsator.
9. Place the fuel sender assembly upside down on the bench.
- Pull the fuel pump downward to remove it from the mounting bracket, then tilt the pump outward and remove the pump and rubber bumper from the pulsator.

CAUTION: DO NOT run the fuel pump unless it is submerged in fuel.

INSTALLATION

1. Assemble the rubber bumper on the fuel; pump.
2. Position the fuel sender assembly upside down.
- Install the fuel pump between the fuel pulse dampener and mounting bracket.
3. Center the fuel pulse dampener between the fuel pump and the fuel feed pipe.
4. Connect the fuel pump electrical connector.
- Always install a new fuel pump strainer when replacing the fuel pump.
5. Support the pump with one hand and position a new pump strainer on the pump in the same position as noted during disassembly.
- Push on the outer edge of ferrule until fully seated.
6. Install the fuel level sender assembly into the fuel tank.
7. Install the fuel tank.
8. Add fuel to the tank and install the fuel filler cap.
9. Connect the negative battery cable.
10. Turn the ignition switch ON for two seconds, then turn it OFF for five seconds. Again turn it ON and check for fuel leaks.