505 In tank pump replacement and fuel sender repair

steve leung (sleung123@juno.com)
Wed, 24 Jun 1998 00:02:41 -0700

I just replaced the in tank fuel pump (just the pump motor) and repaired
a bad low fuel warning switch of the fuel sender in my 84 XN6 sedan.
To get pump and sender out, access from rear deck (speakers) inside the
car is required. Pull rear seats, remove deck, peel back insulation and
you'll see access holes for pump and sender. From the trunk, undo the
lock rings on pump and sender then remove from inside the car.
The monting of the new pump motor is with a short length of fuel hose and
hose clamps. Since the pump motor is not an exact replacement physically
it does not have mounting holes as the OEM one. So the new pump motor is
just hanging from the fuel hose to the metal fuel pickup tube. The new
pump motor have threaded studs for +/- but did not come with hardware. I
scrounged around and luckily found the right size nuts. Crimped two
wires to ring spade lugs and soldered other ends to the terminals on the
pump bracket. Make sure you buzz out +/- and connect them properly. On
the sedan, negative ground is connected to the pump bracket so there is
only one wire (+) on the outside of the assembly after you are done.
Attach pickup screen, reinstall and that's it. Unfortunately the new
pump is very noisy. I thought maybe it was touching the tank so I raised
it a few inches but the noise is still there. I bought two of these pump
motors so I'll have to try the other one next, hopefully it'll be quiet.

The fuel sender may be taken apart by using a dremel to cut the pushed on
internal star lock washer on the bottom of the unit. There was a layer
of crud on the circular contact ring of the low fuel level switch. I
used 600 grit wet dry paper to remove the crud and the switch is working
again. Since I destroyed the star washer by cutting it and did not have
a replacement, I crimped the tube after everything is assembled and
epoxied it to the phenolic bottom so it won't come apart in the tank.

Steve

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