Fuel Pump: Service and Repair

THIS ARTICLE HAS BEEN UPDATED BY TSB # 71-63-04 DATED 8/97.









REMOVAL PROCEDURE

WARNING: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors:
- Use forced air ventilation such as a fan set outside of the trunk.
- Plug or cap any fuel system openings in order to reduce fuel vapor formation.
- Clean up any spilled fuel immediately.
- Avoid sparks and any source of ignition.
- Use signs to alert others in the work area that fuel system work is in process.

WARNING: To prevent personal injury, safety goggles must be worn when working with fuel.

Important: Always replace the fuel sender O-rings when reinstalling the fuel sender assembly. The modular fuel sender assembly will spring-up when the snap ring is removed. When removing the modular fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender assembly is full of fuel. The modular fuel sender assembly must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the modular fuel sender assembly is removed from the fuel tank.

Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
- The fuel pipe connections
- The hose connections
- The areas surrounding the connections


1. Relieve the fuel system fuel pressure.
2. Disconnect the negative battery cable.
3. Drain the fuel tank to no more than 1/4 of a tank full.
4. Remove the spare tire cover, the jack, and the spare tire.

Important: Completely remove the rear compartment carpet before removing the fuel sender access panel.

5. Pull back the trunk liner.
6. Remove the (7) nuts retaining the fuel sender access panel.
7. Remove the fuel sender access panel.
8. Remove the fuel sender electrical connector.
9. Clean the fuel pipes and fuel sender assembly to prevent possible fuel contamination during removal.
10. Remove the quick-connect fittings at the fuel sender assembly.
11. Remove the fuel sender retaining snap ring.
12. Remove the modular fuel sender assembly.
13. Clean the fuel sender assembly O-ring sealing surfaces.
14. Inspect the fuel sender assembly O-ring sealing surfaces.

INSTALLATION PROCEDURE

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.
- Be sure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank.

1. Position the new fuel sender assembly O-ring on the fuel tank.
2. Install the fuel sender assembly into the fuel tank.
3. Install the fuel sender assembly retaining snap ring.
4. Install-the fuel sender electrical connector.
5. Install the quick-connect fittings at the fuel sender assembly.
6. Install the negative battery cable.
7. Install the fuel filler cap.
8. Inspect for leaks.
- Turn the ignition switch to the ON position for 2 seconds.
- Turn the ignition switch to the OFF for 10 seconds.
- Turn the ignition switch to the ON position again.
- Check for fuel leaks.
9. Install the fuel sender access panel.
10. Install the (7) nuts retaining the fuel sender access panel.
- Tighten the fuel sender access panel nuts to 10 Nm (8 lb ft).
11. Reposition the trunk liner.
12. Install the spare tire, the jack, and the spare tire cover.