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6C-68
1977 PONTIAC SERVICE MANUAL
3. If flow is below minimum, check for restriction in the
line.
REMOVAL A N D INSTALLATION OF
ELECTRIC FUEL P U M P
Removal
H Series
C A UTI 0 N: Remove battery negative cable from
battery post before attempting fuel pump removal.
1. Disconnect meter and pump wires at rear wiring
harness connector.
2. Raise vehicle on hoist.
3. Drain fuel tank.
4. Disconnect fuel line hose at gage unit pickup line.
5. Disconnect tank vent line to vapor separator.
6. Remove gage ground wire screw at underbody floor
pan.
7.Remove tank straps bolts and lower tank carefully.
8. Unscrew retaining can ring using Spanner Wrench
J-24187 and remove fuel pump-tank unit assembly.
9. Remove flat wire conductor from plastic clip on fuel
tube.
10. Squeeze clamp and pull pump straight back
approximately one-half inch.
11. Remove two nuts and lockwashers and conductor
wires from pump terminals.
12. Squeeze clamp and pull pump straight back to
remove it from tank unit
-
take care to prevent bending of
circular support bracket.
13. Slide replacement pump through circular support
bracket until it rests against rubber coupling
-
make sure
pump has rubber isolator and saran strainer are attached
(supplied in service package).
14. Attach two conductor wires to pump terminals,
using the two lockwashers and nuts furnished
-
make certain
flat conductor is attached to terminal located on side away
from float arm.
15. Squeeze clamp and push pump into rubber coupling.
16. Replace flat wire conductor in plastic clip on fuel
pickup tube.
lnstallation
1. Install fuel pump-tank assembly in fuel tank. Install
retaining cam ring using Spanner Wrench J-24187.
2. Reinstall wires and fuel tank by reversing removal
steps 1 thru 5.
3. Lower vehicle.
4. Connect battery cable.
5. Start engine and check for leaks.
Removal and lnstallation of Mechanical Fuel
Pump
Removal
All Series
1. Disconnect negative battery cable.
2. Disconnect fuel inlet hose from pump. Disconnect
vapor return hose, if so equipped.
3. Disconnect fuel outlet pipe.
4. Remove two 1/2 inch hex head bolts, using a 3/8 inch
drive deep socket and a ratchet handle.
5. Remove fuel pump.
lnstallation
1. Install new fuel pump with new gasket.
2. bstall two 1/2 inch hex head bolts, turning them in
alternately and evenly.
3. Install fuel outlet pipe. If it is difficult to start fitting,
time can be saved by disconnecting upper end of pipe from
carburetor. Tighten fitting securely, meanwhile holding fuel
pump nut with a wrench. Install and tighten fitting at
carburetor, if removed.
4. Install fuel inlet hose. Install vapor return hose, if so
equipped.
5. Connect negative battery cable.
6. Start engine and check for leaks.
FUEL TANK A N D LINES
Removal and lnstallation of Fuel Tank or Fuel
Gage Tank Unit
All Series (Except "A" Station Wagons)
The fuel gage tank unit is combined with the pickup pipe
and the tank filter. All series require lowering the fuel tank
to replace the tank unit.
To lower a fuel tank, proceed as follows:
1. Disconnect battery.
2. Syphon all fuel from tank into a clean container.
3. Disconnect fuel hose and vapor return hose from gage
tank unit.
4. Remove ground wire screw.
5. Unplug wire from gage unit.
6. Disconnect vent hose.
7. Disconnect support straps and lower tank.
lnstallation
1. To install fuel tank, reverse removal procedure.
To remove fuel gage tank unit, proceed as follows:
1. Unscrew cam ring using Wrench J-24187 for all series.
2. Remove fuel gage tank unit. Install new tank unit,
being careful not to bend or damage it.
3. Complete gage unit installation by reversing above
steps. Make sure electrical connections are clean and tight.
" A Series Wagons
Removal
1. Disconnect battery.
2. Drain gas from tank into suitable container and
disconnect fuel gage tank wire.
3. Raise car on hoist.
4. Remove left rear tire and wheel assembly.
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