Procedure:

1. Remove modular fuel sender as outlined in the appropriate service manual, Section 6C, "Modular Fuel Sender Replacement."

Notice:
Sunbird vehicles affected with contamination will have a gel appearing substance on the fuel sender external strainer. If found, flush fuel tank with warm water for 5 minutes. Remove all water and be certain all water is wiped out of fuel tank by shaking up side down and wiping thoroughly with clean, dry, lint free shop cloths. Add a can of "Fuel Additive" P/N 1051516 to aid in complete removal of all water. If contamination was found, replace fuel filter.

2. Remove external fuel strainer.

3. Remove CPA # 8 (connector position assurance) from electrical connector and disconnect fuel pump electrical connector.





4. Gently release tabs on sides of fuel sender to cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner. (Figure 2)

5. Lift cover assembly out far enough to disconnect the fuel pump electrical connection.

6. Carefully pry snap ring out of groove on fuel pump outlet.


7. Rotate fuel pump baffle # 18 counterclockwise and remove baffle pump assembly from retainer # 7.





8. Replace the fuel pump seal. (Figure 4)

9. Install fuel pump outlet retainer # 21 on fuel pump outlet # 20. Index the snap ring so that the ends are positioned in the groove # 22 facing the fuel pump electrical connection.

10. Install new fuel pump and baffle assembly onto reservoir retainer # 7 and rotate clockwise until seated.


11. Place fuel pump outlet # 20 over retainer # 7 so that snap ring ends # 21 face fuel pump electrical connection and press firmly into place making certain the snap ring is seated and over each tab on outlet.

Important:
Gently pull on fuel pump outlet to assure a secure fastening. If not secure, replace fuel sender. Failure to fully seat retainer snap ring may cause aeration and poor performance.

12. Lower retainer assembly # 7 partially into reservoir. Line up all three sleeve tabs.

Important:
Gently pull on fuel pump reservoir from retainer to assure a secure fastening. If not secure replace entire fuel sender.

13. Install fuel pump connector and CPA # 8 (connector position assurance) to fuel sender cover # 7.

14. Install new external fuel strainer # 14.

15. Reinstall fuel tank in vehicle as outlined in "Modular Fuel Sender Replacement" in the appropriate service manual.