The electric fuel pumps are attached to the fuel sending unit, which is located in the fuel tank.
REMOVAL & INSTALLATION
- Relieve fuel system pressure.
- Disconnect the negative battery cable.
- Raise the vehicle and safely support.
- Drain the fuel tank.
- Disconnect wiring from the tank.
- Remove the ground wire retaining screw from under the body.
- Disconnect all hoses from the tank.
- Support the tank on a jack and remove the retaining strap nuts.
- Lower the tank and remove it.
- Notice the position of the filter for replacement. Support the pump with one hand and grasp the filter with the other. Rotate the filter in one direction, then pull off of the pump. Discard the filter.
- Disconnect the fuel pump connector, on wagons it will not be necessary.
On all models excluding wagons:
- Place the sending unit on a bench upside down, then pull the fuel pump downwards to remove from the mounting bracket. Tilt the pump outwards and remove from the pulsator.
On wagons proceed as follows:
- Disconnect the negative terminal nut and lead (black) from the pump.
- Disconnect the positive lead (gray) from the pump, then loosen the coupler clamps.
On all models excluding wagons:
- Assemble the rubber bumper and insulator onto the pump.
- Position the fuel sender assembly upside down and install the fuel pump between the pulsator and mounting bracket.
- Connect the pump electrical connector.
On all wagon models:
- Position the fuel sender assembly upside down and install the coupler and coupler clamps to the inlet tube, but do not tighten at this time.
- Install the pump between the coupler and the mounting bracket, then tighten the clamps so that 5-8 teeth are engaged.
- Attach the positive lead (gray) to its positive terminal with the nut, then attach the negative lead (black) to the negative terminal.Always install a new filter when installing a new pump.
- Position the pump filter on the new pump and push the outer edge of the ferrule until it is fully seated.
- Install the sending unit.
- Install the gas tank and check for leaks.
- Reconnect the battery cable.
- Relive the fuel system pressure.
- On MFI equipped engines, disconnect the fuel line from the EFI, then connect the fuel line to a pressure gauge.
If the system is equipped with a fuel return hose, squeeze it off so that an accurate reading can be obtained.
- On the MFI equipped engines, connect a jumper wire from the positive battery terminal to the G terminal of the ALCL unit or on the carbureted engines, start the engine, then check the fuel pressure.
- The fuel pressure should be about 34-46 psi.
If the pressures do not indicate correctly, check the fuel line for restrictions or the pump for malfunctions.Volume Test
This test should be completed after the pressure test has been performed.
- Disconnect the pressure gauge from the fuel line and connect a flexible tube from the fuel line to an unbreakable container.
If the engine is equipped with a fuel return line, squeeze off the line to obtain an accurate reading.
- Connect a jumper wire from the positive battery cable to the G terminal of the ALCL unit.
- In 15 seconds, the fuel pump should supply 1 / 2 pint of fuel.
If the fuel volume is below minimum, check the fuel line for restrictions.
- After testing, reconnect the fuel line to the EFI unit.