Fuel Pump: Service and Repair

Descriptive:

CAUTIONS::
- 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.
- Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.
- Always maintain cleanliness when servicing fuel system components.
- Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

REMOVAL PROCEDURE
1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel tank. Refer to Fuel Tank Replacement.
4. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the connections in order to avoid possible contamination of the fuel system.
5. Remove the quick-connect fittings at the fuel sender assembly. Refer to Fuel Line Coupler / Service and Repair / Servicing Quick-Connect Fittings / With Metal Collar.
5. Remove the fuel sender assembly retaining snap ring, the fuel sender assembly and the O-ring from the fuel tank.
7. Discard the fuel sender assembly O-ring.



INSTALLATION PROCEDURE

CAUTION: Always re-attach the fuel lines and fuel filter with all original type fasteners and hardware. Do not repair sections of fuel pipes.

1. Clean the fuel sender assembly O-ring sealing surfaces.
2. Position the new fuel sender assembly O-ring on the fuel tank.

IMPORTANT: Important care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Install the fuel sender assembly and the fuel sender assembly retaining snap ring.
4. Install the quick-connect fittings at the fuel sender assembly. Refer to Fuel Line Coupler / Service and Repair / Servicing Quick-Connect Fittings / With Metal Collar.
5. Install the fuel tank. Refer to Fuel Tank Replacement.
6. Lower the vehicle.
7. Add fuel and install the fuel tank filler pipe cap.
8. Install the negative battery cable.
9. Inspect for leaks:
9.1. Turn the ignition switch to the ON position for 2 seconds.
9.2. Turn the ignition switch to the OFF for 10 seconds.
9.3. Turn the ignition switch to the ON position.
9.4. Visually inspect the fuel system for fuel leaks.