Fuel Pump: Service and Repair

REMOVAL
NOTE: It is not necessary to remove the fuel tank to service the fuel pump/sender unit.
1. Remove the fuel tank cap.
2. Drain the fuel tank until the gauge read less than 1/4 full using a portable gasoline storage/siphon tank, or appropriate substitute.
3. Disconnect the negative battery cable. Raise and support the vehicle.
4. Disconnect the fuel vent, supply, and return hoses from their connections on the fuel pump/sender unit. Disconnect the fuel pump/sender electrical connections at the pump.

Fuel Tank Locking Ring Removal And Hoses:

5. Using a hammer, and brass punch, remove the fuel pump/sender lock ring by tapping it in a counterclockwise direction, until it releases. Remove the pump/sender, remove and discard the pump "O" ring.
DISASSEMBLY

Fuel Pump Assembly Throttle Body Injection:

1. Remove and discard the fuel pump sock style inlet filter. Disconnect the fuel pump terminal wires.
2. Remove the fuel pump outlet hose and clamp, and discard the hose if it shows any signs of wear.
3. Remove the fuel pump top mounting bracket nut, and remove the pump.
ASSEMBLY
1. Place fuel pump top mounting bracket over the top of the pump, and position the pump into the lower bracket. Slide the stud of the top bracket through the hole in the fuel pump side bracket. Install and tighten the fuel pump mounting nut.
2. Install a new fuel pump outlet hose, and secure the hose with a new clamp. Reconnect the wire terminals to the fuel pump motor.
3. Install a new fuel pump sock style filter.
INSTALLATION

Fuel Pump Assembly Installed:

1. Install a new "O" ring on the pump/sender unit, and install the unit into the fuel tank. Be sure that the rubber stopper on the end of the fuel return tube is inserted into the cup in the fuel tank reservoir.
2. Using the hammer and brass punch, install the fuel pump/sender lock ring, and tap it into place in a clockwise direction, until it locks against the stop on the fuel tank.
3. Reconnect the fuel supply, return, and vent hoses, and tighten clamps securely. Reconnect the fuel pump gauge/sender wire connections, then lower the vehicle.
4. Refill the fuel tank, and install the fuel tank cap. Reconnect the negative battery cable, START the engine and check for leaks.