Installation Manual

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Typical In-Tank Electric Fuel Pump Installation Instructions

D. FUEL PUMP INSTALLATION

1. Lubricate the fuel hose and pump outlet with a small

amount of petroleum jelly. Place coupler and clamp

on fuel pump and place second clamp on fuel hose.

2. Place assembly upside-down on bench. Place rubber

insulator on inlet of pump. Install pump and coupler in

same manner as removed, pushing downward on pump

while ﬁtting inlet into mounting bracket. Seat rubber

insulator and pump securely in mounting bracket. Tighten

both clamps securely, if applicable. Reposition foam

rubber sleeve against the insulator.

3. Reconnect electrical terminals to the fuel pump,

making certain polarity is observed (negative (-) terminal

to grounded lead wire). If the pump being replaced had

a Metri-Pac

connector, select the appropriate leads to

match the pump terminals to those on the hanger

assembly.

a) If leads on sending unit have ring terminals for screw

connector, use the enclosed screw, nut, and lock washer

to attach ring terminal to the spade terminals of the pump.

(Torque nuts to 10 in. lbs.)

b) If leads on sending unit have female spade terminals,

make certain they are secure (squeeze sides of terminal

with pliers to provide a tight ﬁt).

c) If the pump being serviced has a welded ground wire

and terminal that won’t ﬁt the pump terminals, it must be

adapted using the wire provided. Simply cut the wire (not

too short!). Strip off a section of the insulation and solder

the replacement wire in place. Do not use electrical tape,

as gasoline will dissolve it.

4. Install the new strainer on the pump in the same position

as original (see step C-1). Push the new strainer straight

on until fully seated by applying pressure to the outer

edge of the metal ferrule, being careful not to damage

the strainer.

5. Inspect the pump to see that it is properly seated on

the insulator and in the mounting bracket.

E. FUEL PUMP AND SENDER ASSEMBLY

INSTALLATION

1. Replace and position assembly in tank; use new

gasket provided.

2. Install cam locking ring and tighten.

3. Reconnect hoses and electrical connectors.

4. Reconnect battery and reﬁll tank.

5. Start car and inspect hose connections and sender

unit gasket for fuel leaks.

CAUTION: Gasoline is involved,

so work in a well ventilated area

away from sparks and open ﬂames.

To reduce the risk of ﬁre and

personal injury, relieve the fuel

system pressure before servicing

fuel system components.

A. FUEL SYSTEM PRESSURE RELIEF

1. Remove the “fuel pump” fuse from the fuse block.

2. Crank engine — engine will start and run until fuel

pressure in tubes is reduced. Engage starter for another

3 seconds to assure relief of any remaining pressure.

3. With ignition “OFF” replace fuel pump fuse. Unless this

procedure is followed, fuel spray could occur when fuel

lines are disconnected.

B. FUEL PUMP AND SENDER

ASSEMBLY REMOVAL

1. Remove the negative cable from the battery.

Have a Class B ﬁre extinguisher near the work area.

2. Drain fuel tank.

3. Disconnect electrical connectors and fuel hoses from

sender assembly.

4. Remove fuel level sender retaining cam ring.

5. Remove fuel level sender assembly from tank.

6. Have the tank professionally cleaned. Dirt, rust and scale,

if not removed, will destroy the pump.

C. FUEL PUMP AND STRAINER REMOVAL

1. Note position of strainer on pump and mark. Remove

strainer by rotating in one direction while pulling off,

and discard.

2. Disconnect electrical terminals from pump.

3. Remove pump from sender assembly.

a) If unit has a pulsator, remove pump by placing

assembly upside down on the bench. Grasp pump and

push downwards. Pull pump inlet away from bracket

and pull pump and pulsator off fuel tube. Discard pulsator.

b) If unit has a rubber hose coupling without pulsator,

remove clamps, cut coupler and discard, then follow

the procedure as in 3a.

NOTE: PULSATOR MAY NOT BE REQUIRED

WITH THE NEW PUMP. USE ONLY THE

HOSE AND CLAMPS PROVIDED. CHECK

INSTRUCTIONS SUPPLIED WITH PUMP FOR

SPECIFIC DIRECTIONS.

AVOID BENDING THE PUMP MOUNTING BRACKET

AND THE FLOAT ARM WHEN HANDLING THE FUEL

LEVEL SENDER.

TO PREVENT DAMAGE TO THE PUMP,

DO NOT RUN PUMP DRY.

WARNING: NOT FOR MARINE, AIRCRAFT,

OR NON-AUTOMOTIVE USE.

Summary of content (11 pages)

PAGE 1
Typical In-Tank Electric Fuel Pump Installation Instructions D. FUEL PUMP INSTALLATION CAUTION: Gasoline is involved, so work in a well ventilated area away from sparks and open flames. To reduce the risk of fire and personal injury, relieve the fuel system pressure before servicing fuel system components. A. FUEL SYSTEM PRESSURE RELIEF 1. Remove the “fuel pump” fuse from the fuse block. 2. Crank engine — engine will start and run until fuel pressure in tubes is reduced.
PAGE 2
Typical Tank Removal / Installation After the positive diagnosis of a failed in-tank electric pump has occurred, the proper service procedure must be followed. Before doing any service work, disconnect the negative battery cable. This will prevent unnecessary arcing. Step 1 Remove as much gasoline from the tank as possible. This should be done using a gas caddy containing a storage tank. The fuel should be disposed of properly or filtered for reuse on the vehicle.
PAGE 3
Universal Pump Locations The universal fuel pump should be mounted below the fuel tank, as all pumps do not have equal lift capabilities. Also, the pump must be mounted below the carburetor to avoid possible vapor lock conditions occurring. Always mount a good quality fuel filter on the inlet side of the pump. Failure to do so will void the warranty.
PAGE 4
Universal Electric Fuel Pump Installation Instructions Rotary Vane BEFORE YOU BEGIN: • Before replacing any electric fuel pump, diagnose the cause of failure. • Dirt is the major cause of pump failure, so the tank must be cleaned out or dirt may cause the replacement pump to fail as well. • Installation of the replacement pump may require that some of the mounting or electrical components be reused. Do not discard any parts.
PAGE 5
Universal Electric Fuel Pump Installation Instructions Rotary Vane OUT Hose Clamps IN (con’t from previous page) 5. Anchor mounting bracket to frame with two selftapping screws. Install the free end of the ground wire to the correct polarity terminal on pump. Press rubber boot firmly onto threaded post, making sure rubber boot seals around plastic washer. PUMP GROUND POLARITY MUST BE SAME AS BATTERY GROUND POLARITY.
PAGE 6
Universal Electric Fuel Pump Installation Instructions Rotary Vane (con’t from previous page) Recreational Vehicle – Vapor Lock Installation Instructions CAUTION: Follow all safety procedures as outlined in pump installation instructions. INSTALLATION STEPS 1. Disconnect the negative battery cable. 2. Locate the pump as near to the fuel tank as possible, near the existing fuel line, and away from any exhaust system components. 3.
PAGE 7
Universal Electric Fuel Pump Installation Instructions Gerotor BEFORE YOU BEGIN: POSITIVE WIRE • Before replacing any electric fuel pump, diagnose the cause of failure. (NOT FURNISHED) NEGATIVE WIRE • Dirt is the major cause of pump failure, so the tank must be cleaned out or dirt may cause the replacement pump to fail as well. FUEL LINE FROM FUEL TANK • Installation of the replacement pump may require that some of the mounting or electrical components be reused. Do not discard any parts.
PAGE 8
Universal Electric Fuel Pump Installation Instructions Solenoid Fig. A BEFORE YOU BEGIN: FUEL FILTER • Before replacing any electric fuel pump, diagnose the cause of failure. • Dirt is the major cause of pump failure, so the tank must be cleaned out or dirt may cause the replacement pump to fail as well. FROM FUEL TANK • To prevent fuel pump failure, installation of a high quality fuel filter on the inlet side of the pump is required.
PAGE 9
Fuel Pressure Regulator Installation Instructions Because of high fuel flow (100 gph) and high fuel pressure (15 psi) it is necessary to install a fuel pressure regulator when installing a P4601HP fuel pump. Failure to do so could cause carburetor flooding, resulting in possible engine damage or a potential explosive condition. This regulator may also be used on other fuel pumps requiring fuel pressure regulation. INSTRUCTIONS 1.
PAGE 10
Mechanical Fuel Pumps Carter® mechanical fuel pumps are available for most domestic and imported passenger cars, trucks, marine and industrial engines. Many of these pumps were original equipment, others are built to meet or exceed OE requirements.
PAGE 11
Mechanical Pump Installation Instructions GM Push Rod Design 2. Check fuel lines and hoses for splits or cracks and the push rod for wear. If necessary, replace worn parts. 2. Install push rod, new gasket, mounting plate and new fuel pump. Make sure the pump lever contacts the end of the push rod and remains in that position during installation as shown in Figure 2.