Fuel Pump: Service and Repair

Fuel Pump/Sender Exploded View:

For removal of the Fuel sender/fuel pump assembly from the fuel tank, refer to Fuel Tank Replacement Procedure.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. For removal of the Fuel sender/fuel pump assembly from the fuel tank, refer to Fuel Tank Replacement Procedure.
3. Note position of fuel pump strainer on fuel pump.
4. Support sender with one hand and grasp strainer with other hand.
- Rotate strainer in one direction and pull off of pump. Discard strainer after inspection.
- Inspect fuel pump strainer. If strainer is contaminated, it must be replace and the fuel tank should be cleaned.

5. Loosen clamp and remove connecting hose from fuel pump outlet.
6. Terminal retainer.
7. Fuel pump electrical connector and electrical connector from bottom of sender cover.
8. Retainer clip from fuel return pipe.
9. Fuel pump and fuel level sender assembly and spring from fuel sender.
10. Housing cover from fuel pump housing.
11. Fuel pump.
12. If the fuel level sensor is being replaced, slide fuel level sensor from retainers on fuel pump housing.

ASSEMBLE
1. Fuel level sensor to fuel pump housing.
2. Fuel pump and isolator into fuel pump housing.
3. Align: Small hole kin the housing cover aligns over the fuel level sensor.
4. Housing to fuel pump housing.
5. Slide fuel pump and fuel level sensor assembly and spring onto return pipe.

CAUTION: Fuel pump and fuel level sender assembly must be aligned directly over fuel sender cover.

6. Compress spring and install retainer clip through fuel return pipe.
7. Connect hose to fuel pump outlet.
8. Tighten clamps (2) so that 5 to 8 teeth are engaged.
9. Fuel pump electrical connector and electrical connector to bottom of sender cover.
10. Terminal retainer.
11. New fuel pump strainer.
12. Support sender with one hand and position new pump strainer on pump in same position as noted during disassembly. Push on outer edge of ferrule until fully seated.

INSTALL OR CONNECT
Fuel sender into fuel tank and reinstall fuel tank. For replacement of the Fuel sender/fuel pump assembly into the fuel tank, refer to Fuel Tank Replacement Procedure.