Fuel Pump: Service and Repair

Fuel Sender Assembly Replacement:

Fuel Sender Assembly:

Remove or Disconnect:
1. Relieve fuel system pressure
2. Drain fuel tank
3. Remove fuel tank assembly
4. Remove fuel sender assembly

Disassemble
1. Note position of fuel pump strainer on fuel pump
2. Support sender with one hand and grasp strainer with other hand. Rotate strainer in one direction and pull off of pump. Discard strainer after inspection.
3. Loosen clamp and remove connecting hose from fuel pump outlet
4. Remove terminal retainer
5. Disconnect fuel pump electrical connector and electrical connector from bottom of sender cover
6. Remove retainer clip from fuel return pipe
7. Remove fuel pump and level sensor assembly and spring from fuel sender
8. Remove housing cover from fuel pump housing
9. Slide fuel level sensor from retainers on fuel pump housing


Inspect
1. Fuel pump strainer. If strainer is contaminated, it must be replaced and the fuel tank should be removed and cleaned.
2. Fuel pump inlet for dirt and debris. If found, fuel pump should be replaced.




Assemble
1. Install fuel level sensor to fuel pump housing
2. Install fuel pump and isolator into fuel pump housing
3. Connect housing cover to fuel pump housing
4. Slide fuel pump and fuel level sensor assembly and spring onto fuel return pipe
5. Depress spring and install retainer
6. Connect hose to outlet and tighten clamp so that 5-8 teeth are engaged
7. Connect fuel pump electrical connector and electrical connector to bottom of sender cover
8. Install terminal retainer
9. Support sender with one hand and position new pump strainer on pump in same position as noted during disassembly


Install or Connect:
1. Install fuel sender assembly
2. Install fuel tank assembly

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.