Fuel Pump/Fuel Tank Sender Replacement

Fuel Pump/Sending Unit Installation:

Fuel Sender/Pump Assembly In Fuel Tank.:

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Drain the fuel tank, refer to MAINTENANCE PROCEDURES/FUEL TANK DRAINING.
4. Remove the fuel tank, refer to FUEL TANK AND FUEL LEVEL SENDING UNIT.
5. Using tool J 24187 or equivalent, remove the fuel level meter assembly retaining cam, fuel level meter assembly and O-ring from the tank. Discard the O-ring.
6. Note the position of the fuel pump filter on the fuel pump.
7. Support the pump with one hand and grasp the filter with the other hand.
^ Rotate the filter in one direction and pull the filter off of the pump. Discard the filter.
8. Disconnect the fuel pump electrical connector.
9. Loosen the pulsator.
10. Place the fuel level meter assembly upside down on the bench.
^ Pull the pump downward to remove it from the mounting bracket, then tilt the pump outward and remove the pump and rubber bumper from the pulsator.

CAUTION: DO NOT run the fuel pump unless it is submerged in fuel.

INSTALLATION:

1. Install the rubber bumper on the fuel pump.
2. Position the fuel level meter assembly upside down.
^ Install the fuel pump between the pulsator and the mounting bracket.
3. Center the pulsator between the fuel pump and fuel feed tube.
4. Connect the fuel pump electrical connector.
^ Always install a new fuel pump filter when replacing the fuel pump.
5. Support the fuel pump with one hand and position the new pump filter on the pump in the same position as noted during disassembly.
^ Push on the outer edge of the ferrule until fully seated.
6. Inspect and clean:
^ Using a clean shop towel, wipe off the male tube ends.
^ Inspect all connectors for dirt and damage. Clean or replace components/assemblies as required.
^ Clean all O-ring surfaces.

CAUTION: Care should be taken not to fold over or twist the fuel pump filter when installing the fuel level meter assembly as this will restrict fuel flow. Also, assure that the fuel pump filter does not block full travel of the float arm. Position the filter as shown in the image.

7. Install a new O-ring on the fuel tank.
8. Install the fuel level meter assembly and fuel level meter assembly retainer cam using tool J 24187 or equivalent.
9. Install the fuel tank.
10. Add fuel and install the fuel filler cap.
11. Connect the negative battery cable.
12. Turn the ignition switch "ON" for two seconds, then turn it "OFF" for five seconds. Again, turn the ignition switch "ON" and check for fuel leaks.