Fuel Pump: Service and Repair

Fuel Tank Mounting:

NOTE: The fuel pumps are serviced together as an assembly. If the fuel pumps are non-functional, the fuel level meter assembly must be replaced.

REMOVAL

1. Relieve the fuel system pressure. See Fuel System Pressure Relief.
2. Use a hand operated pump and hose inserted through the filler neck, to drain as much fuel from the tank as possible.
3. Remove the filler door bezel attaching screws and bezel.
4. Remove the fuel filler cap.
5. Lift the fuel tank filler neck housing and disconnect the drain hose from the nipple.

NOTE: Clean all fuel connections and surrounding areas before disconnecting to avoid possible contamination of the fuel system.

6. Remove the fuel tank filler neck housing.
7. Disconnect the fuel level meter assembly electrical connector.
8. Disconnect and plug fuel feed hose, return hose, and vapor hose.
9. Remove sender assembly attaching screws and remove sender from tank.

Fuel Sender Assembly:

10. Note the position of the fuel strainer on the fuel pump.
11. Support the pump with one hand and grasp the filter with the other hand.

^ Rotate the filter in one direction and pull it off of the pump. Discard the filter.

12. Disconnect the fuel pump electrical connector.
13. Place the fuel level meter assembly upside down on the bench. and pull the pump downward to remove from the mounting bracket, then tilt the pump outward and remove it from the pulsator.

CAUTION: DO NOT run the fuel pump unless submerged in fuel.

^ Inspect the fuel pump inlet for debris and dirt. If found, the fuel pump should be replaced.

INSTALLATION

1. Assemble the rubber bumper and rubber insulator on the fuel pump.
2. Position the fuel level meter assembly upside down.

^ Install the fuel pump between the pulsator and the mounting bracket.

3. Connect the fuel pump electrical connector.

NOTE: Always install a new pump filter when replacing the fuel pump.

4. Install the new pump filter in the same position as noted during disassembly. Push on the outer edge of the ferrule until fully seated.
5. Position a new gasket on the fuel tank with the notch facing forward in the right hand corner of the fuel tank.
6. Install the fuel level meter assembly in the fuel tank and connect all fuel and vapor hoses.
7. Connect the negative battery cable.
8. Turn the ignition switch ON for two seconds, then turn it OFF for ten seconds. Again turn the ignition switch ON and check for fuel leaks.