Fuel Pump: Service and Repair

Descriptive:

Removal Procedure

CAUTION: Do Not handle the fuel sender assembly by the fuel pipes. Due to the length of the fuel pipes, the amount of leverage generated by handling the fuel pipes could damage the joints.

NOTE: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly.

Tool Required: J 35731 Fuel Sender Spanner Wrench.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Release.
2. Drain the fuel tank.
3. Remove the fuel tank.
4. Clean all of the fuel pipe connections.
5. Clean all of the hose connections.
6. Remove the quick-connect fittings at the fuel sender assembly.
7. Using the J 35731 Fuel Sender Spanner Wrench, remove the fuel sender assembly retaining cam, the fuel sender assembly and the O-ring from the fuel tank. Discard the fuel sender assembly O-ring.

Installation Procedure

NOTE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. General Motors will call out those fasteners that require a replacement after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.

CAUTION: UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

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

NOTE: 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 retainer cam using the J 35731 Fuel Sender Spanner Wrench
4. Install the quick-connect fittings at the fuel sender assembly.
5. Install the fuel tank.
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 again.
9.4. Check for fuel leaks.