Fuel Pump: Service and Repair

The OEM service manual does not provide fuel pump service and repair information. Refer to Fuel Sender Assembly.

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
1. J 34730-1A Fuel Pressure Gauge
2. J 39765 Fuel Sender Locknut Wrench

REMOVAL PROCEDURE

CAUTION:
^ Provide proper ventilation when working with fuel in enclosed areas where fuel vapors can collect. The lack of adequate ventilation may result in personal injury.
^ Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.




1. Relieve the fuel system fuel pressure. Refer to the Fuel Pressure Relief Procedure.
2. Drain the fuel tank to at least 3/4 of a tank full. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

IMPORTANT: The modular fuel sender support assembly will spring-up when the locking ring is moved.

4. Remove the fuel sender assembly using J 39765 Fuel Sender Locknut Wrench.

DISASSEMBLE PROCEDURE




1. Note the position of the fuel sender strainer for installation (2).
2. Support the reservoir with one hand and grasp the fuel sender strainer with the other hand.
3. Pull the fuel sender strainer off of the fuel sender assembly.
4. Inspect the fuel sender strainer. If the fuel sender strainer is contaminated, the fuel tank should be cleaned.
5. Discard the fuel sender strainer after inspection.




6. Disassemble the electrical connectors from the sensor assembly of the fuel pump and the cover assembly.
7. Disassemble the fuel level sensor assembly (3).

ASSEMBLE PROCEDURE




1. Assemble the fuel level sensor assembly.
2. Assemble the electrical connectors to the fuel pump and the cover assembly.




3. Position the new fuel sender strainer (2) on the modular fuel sender and push on the outer edge of the fuel sender strainer until the fuel sender strainer is fully seated.

INSTALLATION PROCEDURE




1. Install the fuel sender assembly (1) into the fuel tank.
2. Install new lip seal on modular fuel sender assembly. Always use a new lip seal when servicing modular fuel sender unit.
3. Lightly lubricate the inside diameter of the lip seal with clean engine oil.
4. Install modular fuel sender assembly (1) into the fuel tank.
5. Seat the lip seal into tank opening.
6. Install the fuel sender locking ring using J 39765 Fuel Sender Locknut Wrench.
7. Align arrow on top of the fuel sender cover to arrow on the fuel tank.

Refer to Fastener Notice in Service Precautions.

8. Slowly apply pressure to the top of the spring loaded sender until the lip seal is flush between the fuel tank and the fuel sender cover.

IMPORTANT: Be sure that the lip seal provides a snug seal between the modular unit and the fuel tank.

9. Tighten the locking nut.
10. Reinstall the fuel tank.




11. Lower the vehicle.
12. Add fuel to the fuel tank.
13. Reinstall the fuel tank filler pipe cap.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

14. Connect the negative battery cable.
15. Inspect for fuel leaks.
15.1. Turn ignition switch to ON for 2 seconds.
15.2. Turn the ignition switch to OFF for 5 seconds.
15.3. Turn the ignition switch ON.
15.4. Check for fuel leaks.
16. Reinstall intake manifold sight shield.