Service

Modular Sender:

FUEL PUMP STRAINER 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. Refer to "Fuel Tank Draining"[1][2]Fuel Tank Draining.
4. Fuel tank. Refer to "Fuel Tank Assembly Remove & Replace.
5. Fuel sender assembly. Refer to "Modular Fuel Sender Assembly"Remove & Replace.
6. Note strainer position for future reference.
7. Support the reservoir with one hand and grasp the strainer with the other hand.
8. Using a screw driver to pry the strainer ferrule off the reservoir.
9. Discard the strainer.

Install or Connect
1. New strainer to reservoir.
2. Support the reservoir with one hand and grasp the strainer with the other hand twisting strainer into position noted in step 6.
3. Install Fuel sender assembly.
4. Install Fuel tank.
5. Refill tank.

Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.

FUEL LEVEL SENSOR REPLACEMENT

Remove or Disconnect
1. Perform steps 1 through 5 under Fuel Pump Strainer Replacement.
2. Remove fuel level sensor from modular fuel sender.

Install or Connect
1. Fuel level sensor to modular fuel sender.
2. Install fuel sender assembly.
3. Install fuel tank.
4. Refill tank.

Turn ignition to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position, and check for fuel leaks.

Removal Modular Sender Cover:

FUEL PUMP REPLACEMENT

Remove or Disconnect

Note: Always replace the fuel pump outlet seal whenever the fuel pump is removed for the modular sender.

1. Perform steps 1 through 8 under Fuel Pump Strainer Replacement.
2. Remove CPA (connector position assurance) from electrical connector and disconnect fuel pump electrical connector.

Removal Modular Sender Cover:

3. Gently release tabs on sides of fuel sender to cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner. Refer to Figure 14.
4. Lift cover assembly out far enough to disconnect the fuel pump electrical connection.

Fuel Pump And Baffle:

5. Rotate fuel pump baffle counterclockwise and remove baffle and pump assembly from retainer. Refer to Figure 13.
6. Slide fuel pump outlet out of slot.
7. Fuel pump outlet seal.

Fuel Pump Outlet Seal:

Install or Connect
1. Fuel pump outlet seal. Refer to Figure 16.
2. Slide fuel pump outlet in slots of reservoir cover
3. Fuel pump and baffle assembly onto reservoir retainer and rotate clockwise until seated.
4. Lower retainer assembly partially into reservoir. Line up all three sleeve tabs. Press retainer onto reservoir making sure all three tabs are firmly seated.

IMPORTANT: Gently pull on fuel pump reservoir from retainer to assure a secure fastening. If not secure replace entire fuel sender.

5. Fuel pump connector
6. CPA (connector position assurance) to fuel sender cover.
7. Install new external fuel strainer.
8. Install modular fuel sender.
9. Install fuel tank.