Fuel Pump: Service and Repair

Fuel Sender Components:

CAUTION:
- Do Not handle the fuel sender by the fuel pipes. Due to the length of the pipes, the amount of leverage generated by handling the pipes could damage the solder joints.
- Always replace fuel sender O-rings when reinstalling fuel sender assembly.

REMOVE OR DISCONNECT
1. Relieve fuel system pressure. Refer to Fuel System / Service and Repair. [1][2]Fuel System Pressure Relief Procedure
2. Drain fuel tank.
3. Fuel tank.
4. Fuel sender assembly.

DISASSEMBLE

Fuel Pump Strainer
1. Note position of fuel strainer for installation. Support pump with one hand and grasp strainer with other hand.
- Pull strainer off of pump. Discard strainer after inspection.

Inspect
- Fuel pump strainer. If strainer is contaminated, the fuel tank should be cleaned.
- Fuel pump inlet for dirt and debris. If found, fuel pump should be replaced.

Fuel Pump
2. Fuel pump electrical connector.
3. Place fuel sender assembly upside down on bench.
4. Pull fuel pump downward to remove from mounting bracket, then tilt pump outward and remove from fuel feed pipe.

CAUTION: Do Not run fuel pump unless submerged in fuel.

FUEL SENDER
1. Transfer fuel pump to new fuel sender.

ASSEMBLE
1. Rubber insulator on fuel pump.
2. Position fuel sender assembly upside down.
- Install fuel pump between fuel feed pipe and mounting bracket.
3. Fuel pump electrical connector.

NOTICE: Always install a new pump strainer when installing fuel pump.

4. New fuel pump strainer on fuel pump and push on outer edge of ferrule until fully seated.

INSTALL OR CONNECT
1. Fuel sender assembly.
2. Fuel tank.
3. Add fuel and install fuel filler cap.

INSPECT
Turn ignition switch to "ON," position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.