Disassembly/Assembly

Fuel Sender Assembly:

Removal

1. Negative battery cable.
2. Relieve fuel system pressure (see "Fuel System Pressure Relief").
3. Drain and remove fuel tank (see Fuel Tank Replacement").
4. Fuel sender assembly (see "Fuel Sender Assembly Replacement").

Disassembly

1. Note position of fuel pump strainer on fuel pump.
2. Support pump with one hand and grasp strainer with other hand.
^ Rotate strainer in one direction and pull off of pump. Discard strainer after inspection.
^ Remove deflector.

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

If fuel pump is being replaced, proceed to step 3.

3. Fuel pump electrical connector.
4. Place fuel sender assembly upside down on bench. Pull fuel pump downward to remove from mounting bracket, then tilt pump outward and remove from connecting hose or fuel pulse dampener.
5. Remove connecting hose and clamps (2).

NOTICE: Do not run fuel pump unless submerged in fuel.

If fuel pulse dampener is being replaced, proceed to step 7.

6. Note position of fuel pulse dampener on inlet pipe, then remove fuel pulse dampener from pipe.

Inspect
^ Dry fuel pulse dampener with a shop towel.
^ Shake fuel pulse dampener, while listening for trapped fuel movement inside.
^ If fuel is heard inside fuel pulse dampener, replace.

If fuel sender is being replaced, proceed to step 8.

7. Transfer fuel pump, deflector, and fuel pulse dampener to new fuel sender.

Assembly

1. Install new connecting hose and clamps (2) on fuel feed tube (do not tighten clamps at this time), or fuel pulse dampener.
2. Position fuel sender assembly upside down. Install fuel pump between connecting hose or fuel pulse dampener and mounting bracket.
3. Connect fuel pump electrical connector.

Important: Always install a new pump strainer when replacing fuel pump.

4. Support pump with one hand and position deflector on fuel pump. Assemble new pump strainer in same position as noted during disassembly. Push on outer edge of ferrule until fully seated.


Installation

1. Install fuel sender assembly (see "Fuel Sender Assembly Replacement").
2. Install fuel tank (see " Fuel Tank Replacement").
3. Add fuel and install fuel filler cap.
4. Reconnect negative battery cable.

Inspection

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.