Fuel Pump: Service and Repair

REMOVAL PROCEDURE

CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.




1. Remove the fuel sender assembly from the fuel tank.
2. Disconnect the fuel level sensor (gauge sender) electrical connector (1) from the fuel sender assembly.

IMPORTANT: Do not apply pressure to the fuel level sensor resistor plate or float arm. Pressure can deform these parts and cause them to operate incorrectly.




3. Depress the retaining tab (1) and slide the fuel level sensor assembly down in order to remove the sensor from the fuel sender assembly.




4. Remove the lower assembly end cap (1) by releasing the three snap-fit catches with a screwdriver (2).




5. Remove the fuel pump cushion (1).




6. Disconnect the two fuel pump electrical connections (1) from the fuel sender subassembly.




7. Pull the fuel pump (1) firmly down out of the fuel sender assembly housing (2).

INSTALLATION PROCEDURE

IMPORTANT: Check that the fuel tube and grommets are still correctly installed in the fuel sender subassembly. If service to the fuel tube and grommets is necessary, refer to Fuel Sender Assembly Service.




1. Install the spacer (2) onto the fuel pump outlet pipe.




2. Install the fuel pump (1) up through the housing (2) and into the fuel sender subassembly, aligning the fuel pump outlet pipe with the fuel tube in the subassembly.




3. install the fuel pump cushion (1) between the fuel pump and the lower assembly end cap.
4. Attach the lower assembly end cap to the housing, being sure to interlock the three snap-fit catches.




5. Connect the two fuel pump electrical connectors (1) to the fuel sender assembly.




6. Insert the locating tab (1) on the fuel level sensor assembly into the channel (2) on the fuel sender assembly and slide upward until locked in place.




7. Connect the fuel level sensor electrical connector (1) to the fuel sender assembly.
8. Install the fuel sender assembly into the fuel tank.