Chevrolet 25003646 Fuel Tank Meter/Pump SENDER

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The initial steps involve checking the fuel tank to ensure it has enough fuel.

The first step is to disconnect the battery cable.

For carbureted models, first check the fuel tank to ensure there is enough fuel. Then, while the engine is running, inspect all fuel lines for leaks, loose connections, or any damage. Make sure there are no air leaks before the fuel pump, as this can affect its performance. Next, disconnect the fuel line into the carburetor and crank the engine to see if there is a strong spurt of gasoline from the line. If not, check for clogs or issues with the fuel pump. To test the fuel pump flow capacity, use a measuring container and a watch to see if the pump can pump one pint of gasoline in 30 seconds or less. For fuel injected models, start by verifying that the fuel pump is running by listening for a whirring noise when the ignition switch is turned on. If the pump does not come on, check the fuel pump fuse and relay. If they are both functioning properly, check for an open circuit between the relay and the fuel pump. If the circuit is fine, disconnect the electrical connector at the fuel pump and connect battery voltage to the gray wire terminal of the pump. If the pump runs, it is okay; otherwise, it needs to be replaced. To test the fuel pump relay, disconnect it and connect a test light to the ignition wire. When the key is turned on, the test light should come on for a few seconds and then turn off. Use a jumper wire to connect the ignition wire to the fuel pump wire on the relay connector and check if the fuel pump activates. If it does not, replace the fuel pump relay. To check the fuel pump pressure, relieve the fuel system pressure and attach a fuel pressure gauge to the appropriate location (either the fuel feed line or the Schrader valve fitting on the fuel rail). Turn the ignition key to on and check the fuel pressure on the gauge. If the pressure is low, the fuel pressure regulator may be defective. If the pressure is too high, check for a restricted fuel line or a defective regulator. On MPFI models, start the engine and remove the vacuum hose to the pressure regulator to see if the fuel pressure increases; if not, the regulator is likely defective.

After removing the fuel tank, the fuel pump/sending unit assembly should be unlocked by turning the inner ring counterclockwise and then lifted from the tank.

After separating the fuel pump from the sending unit, the assembly should be inserted back into the fuel tank and the inner lock ring should be turned clockwise to engage the locking cams.