Service

Fuel Sender Assembly Replacement:

NOTICE: Do not handle the fuel sender by the fuel tubes. Due to the length of the tubes, the amount of leverage generated by handling the tubes could damage the solder joints.

Remove or Disconnect
1. Negative battery cable.
2. Relieve fuel system pressure (see "Fuel System Pressure Relief"[1][2]Fuel System Pressure Relief Procedure).
3. Drain fuel tank (see "Fuel Tank Draining"Fuel Tank Draining Procedure).
4. Fuel tank (see "Fuel Tank Assembly Remove & Replace").
5. Fuel sender assembly (see "Fuel Sender Assembly ReplacementRemove & Replace").

Disassemble
1. 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.

Inspect

^ Fuel pump strainer. If strainer is contaminated, the fuel tank should be cleaned.
^ Fuel pump inlet for dirt and debris. if found, fuel pump should be replaced.


Fuel Pump Replace
2. Fuel pump electrical connector.
3. Place fuel sender assembly upside clown on bench.

^ Pull fuel pump downward to remove from mounting bracket, then tilt pump outward and remove from fuel pulse dampener.

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

Fuel Pulse Dampener Replace
4. Note position of fuel pulse dampener on inlet tube, then remove fuel pulse dampener from tube.

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.
^ Fuel pump strainer. if strainer is contaminated, the fuel tank should be cleaned.
^ Fuel pump inlet for dirt and debris. if found, fuel pump should be replaced.

Fuel Sender Replace
5. Transfer fuel pump and fuel pulse dampener to new fuel sender.

Assemble
1. Fuel pulse dampener in same position as noted during disassembly.
2. Rubber bumper and rubber insulator on fuel pump.
3. Position fuel sender assembly upside down.

^ Install fuel pump between fuel pulse dampener and mounting bracket.

4. Fuel pump electrical connector.

Important

^ Always install a new pump strainer when installing fuel pump.

5. New fuel pump strainer on fuel pump and push on outer edge of ferrule until fully seated.

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

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.