Fuel Pump Replacement

Fuel Sender Assembly Replacement:

Fuel Sender Assembly (Typical):

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve fuel system pressure. Refer to Fuel System Pressure Relief Procedure. Fuel System Pressure Relief Procedure
3. Drain fuel tank. Refer to Fuel Tank/Service and Repair/ Draining Fuel Tank. Fuel Tank Draining Procedure
4. Fuel tank. Refer to Fuel Tank/Service and Repair/Fuel Tank Replacement. Fuel Tank Replacement
5. Fuel sender assembly attaching nuts, retaining flange, fuel sender assembly and O-ring from fuel tank. Discard O-ring.

DISASSEMBLE
1. Note position of fuel pump strainer on fuel pump.
2. 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.

NOTE:
- If during inspection fuel strainer contamination is present, the fuel tank should be cleaned.
- If any dirt or debris is observed at the fuel pump inlet, the pump should be replaced.

3. Loosen clamp and remove connecting hose from fuel pump outlet.
4. Terminal retainer.
5. Fuel pump electrical connector and electrical connector from bottom of sender cover.
6. Retainer clip from fuel return pipe.
7. Fuel pump and fuel level sensor assembly and spring from fuel sender.
8. Housing cover from fuel pump housing.

CAUTION: Do not run fuel pump unless submerged in fuel.

9. Fuel pump.

ASSEMBLE
1. Fuel level sensor to fuel pump housing.
2. Fuel pump and isolator into fuel pump housing.

NOTE: Small hole in the housing cover aligns over the fuel level sensor.

3. Connect cover to fuel pump housing.
4. Slide fuel pump and fuel level sensor assembly and spring onto fuel return pipe.
5. Compress spring and install retainer clip through fuel return pipe.
6. Fuel feed hose to fuel pump outlet. Tighten clamps so that 5 to 8 teeth are engaged.
7. Fuel pump electrical connector and electrical connector to bottom of sender cover.
8. Terminal retainer.

NOTE: Always install a new pump strainer when replacing fuel pump.

9. New pump strainer in same position as noted during disassembly. Push on outer edge of strainer ferrule until fully seated.

INSTALL OR CONNECT
1. Fuel sender assembly. Refer to Fuel Sender Assembly/Service and Repair. [1][2]Fuel Sender Assembly Replacement
2. Fuel tank.
3. Add fuel and install fuel filler cap.
4. Negative battery cable.

INSPECT
Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.