Electric Fuel Pump - REMOVAL & INSTALLATION
The fuel
pump is located inside the fuel tank. It is part of a so-called 'fuel
pump module' or 'fuel sender assembly' which includes the fuel pump, the
fuel tank gauge sending unit, the fuel pump strainer and related
components. These fuel pump module assemblies are expensive. Be sure of
the diagnosis before attempting this procedure to replace a fuel pump.
On
some vehicles covered by this guide, the fuel sender assembly can be
accessed through a removable panel on the trunk floor. On others, the
fuel tank must be removed. The spare tire and trunk carpet have to be
removed to expose the trunk floor access panel to see which is the
proper procedure to use on your vehicle.
With Trunk Access Panel
CAUTION
Observe all applicable safety precautions when working around
fuel. Whenever servicing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or vapors to come in contact
with a spark or open flame. Keep a dry chemical fire extinguisher near
the work area. Always keep fuel in a container specifically designed for
fuel storage; also, always properly seal fuel containers to avoid the
possibility of fire or explosion. Wear safety glasses to protect the
eyes from fuel splash.
NOTE
Always replace the fuel sender O-rings when reinstalling the fuel
sender assembly. Note that the module assembly is spring loaded and it
will spring-up when the retaining snapring is removed.
WARNING
When removing the modular fuel sender assembly from the fuel tank,
the reservoir bucket on the fuel sender assembly is full of fuel. The
sender assembly must be tipped slightly during removal to avoid damage
to the float. Place any remaining fuel into an approved container once
the sender assembly is removed from the fuel tank.
Fig. Some vehicles have access panels built into the trunk floor
so the fuel pump/sender module can be removed without having to remove
the fuel tank
CAUTION
Do not handle the fuel sender assembly by the fuel pipes. The pipe
joints are very fragile. The amount of leverage generated by handling
the fuel pipes could damage the joints.
To install:
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, make sure that the fuel pump strainer does not block
the full travel of the fuel gauge float arm.
continue...
Without Trunk Access Panel
CAUTION
Observe all applicable safety precautions when working around
fuel. Whenever servicing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or vapors to come in contact
with a spark or open flame. Keep a dry chemical fire extinguisher near
the work area. Always keep fuel in a container specifically designed for
fuel storage; also, always properly seal fuel containers to avoid the
possibility of fire or explosion. Wear safety glasses to protect the
eyes from fuel splash.
NOTE
On Oldsmobile models, a special tool, J 35731 Fuel Sender Spanner
Wrench is required to disengage the fuel sender assembly. On Chevrolet
models, a snapring is usually used to retain the spring-loaded module
assembly which will spring-up when the retaining snapring is removed.
Always replace the fuel sender O-ring when reinstalling the fuel sender
assembly.
WARNING
When removing the modular fuel sender assembly from the fuel tank,
the reservoir bucket on the fuel sender assembly is full of fuel. The
sender assembly must be tipped slightly during removal to avoid damage
to the float. Place any remaining fuel into an approved container once
the sender assembly is removed from the fuel tank.
Fig. On applications with extra-long fuel pipes, the fuel tank has
to be removed to service the fuel sender module
Relieve the fuel system pressure using the procedures found in
this section.
Disconnect the negative battery cable.
Drain the fuel tank into a suitable container.
Raise and safely support the vehicle.
Remove the fuel tank using the procedures found in this section.
As the tank is being lowered, clean the fuel pipes and the fuel sender
assembly to prevent possible fuel contamination. Remove the
quick-connect fittings at the fuel sender assembly. Information on
servicing these fittings is found in the section. Detach the electrical
connector and with an assistant, lower the fuel tank to the floor.
On Oldsmobile vehicles use J-35731 Fuel Sender Spanner Wrench, or
equivalent, to remove the fuel sender assembly retaining cam (lock
ring). Then remove the sender assembly and O-ring. Discard the O-ring.
On Chevrolet vehicles, remove the fuel sender assembly retaining
snapring. Expect the sender to spring-up when the snapring is removed.
CAUTION
Do not handle the fuel sender assembly by the fuel pipes. The
joints are very fragile. The amount of leverage generated by handling
the fuel pipes could damage the joints. This is especially true of some
Oldsmobile application which use long fuel pipes which are easily
damaged.
Carefully remove the sender assembly. Inspect and clean the O-ring
sealing surfaces.
To install:
Hope this help to solve it; TY for using Fixya (remember rated and comment this).
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, make sure that the fuel pump strainer does not block
the full travel of the fuel gauge float arm.
Position the new fuel sender assembly O-ring on the tank and
carefully install the sender assembly into the fuel tank.
On Oldsmobile applications use a suitable fuel sender spanner
wrench, to properly tighten the sender assembly retainer cam.
On Chevrolet applications, install the retaining snapring. Be sure
the snapring is fully seated within the tab slots on the fuel tank.
With an assistant, raise the tank and assemble the electrical
connector to the sender assembly. Install the quick-connect fittings to
the sender assembly. Finish installing the fuel tank using the
procedures found in this section. Take care that all insulators and heat
shields are in place.
Lower the vehicle. Add fuel, connect the negative battery cable
and install the fuel filler cap.
Inspect for leaks using the following procedure:
Turn the ignition switch to the
ON
position for 2 seconds.
Turn the ignition switch to the
OFF
position for 10 seconds.
Turn the ignition switch to the
ON
position again.
Inspect all areas for fuel leaks.
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