Replacing Electric Fuel Pump: Step-By-Step Guide For Diyers

Changing an electric fuel pump can be a challenging task, but it is possible to do it yourself if you take the right precautions. Electric fuel pumps are small electric motors that transfer fuel from the fuel tank to the engine. They are located inside the fuel tank in most vehicles with electronic fuel injection. Before attempting to replace an electric fuel pump, it is important to rule out other potential issues, such as a plugged fuel filter, restricted fuel line, or bad fuel pump relay. If you decide to replace the pump, it is crucial to work in a well-ventilated area to minimise the risk of fire and inhalation of harmful fumes. It is also important to wear safety gear, such as safety glasses and gloves, to protect yourself from fuel spills and splashes. Additionally, draining the fuel tank before beginning the replacement process can reduce the risk of spills and make the tank easier to handle. When installing a new electric fuel pump, it is important to ensure that the wiring and grounding are correct to prevent pump failure.

Electric fuel pump safety

Work in a Safe Environment:

• Ensure the work area is well-ventilated to prevent the buildup of flammable fuel vapors.
• Keep away from open flames, sparks, or any potential sources of ignition, including pilot lights and incandescent light bulbs.
• Do not smoke near the vehicle or fuel tank.
• Have a fire extinguisher readily available in case of emergencies.

Personal Protective Equipment:

• Wear safety glasses to protect your eyes from any debris or fuel splashes.
• Wear gloves to protect your hands and avoid direct contact with fuel or chemicals.

Fuel Handling:

• Before beginning any work, relieve fuel pressure to prevent accidental release, which could cause a fire or injury.
• Use approved containers, such as gas caddies or gas cans, to store or drain fuel. Never use open buckets.
• Do not leave open containers of gasoline unattended.
• When siphoning fuel, use a hand siphon pump instead of an electric drill-powered pump to avoid sparks.
• Never suck on the hose to start a siphon as gasoline fumes can be harmful to your lungs.
• Keep fuel containers below the level of the tank during the draining process.

Vehicle Preparation:

• Set the parking brake and place the transmission in park (in gear for manual transmission).
• Block the front wheels to prevent the vehicle from rolling.
• Raise the vehicle using a jack and support it with jack stands rated for the vehicle's weight.
• Never crawl under a vehicle supported only by a jack.
• Disconnect the battery before starting any work.

Fuel System Precautions:

• Inspect the fuel pump wiring for loose, corroded, or damaged connectors, as these can reduce current to the pump and cause issues.
• Ensure proper grounding of the electric fuel pump to prevent overheating and failure.
• Avoid mounting the pump near heat sources, such as the exhaust system.
• Consider using an oil pressure switch to automatically shut off the pump when the engine is off, preventing the continuous spraying of fuel in the event of a crash or fuel line failure.

Safety should always be the top priority when working with electric fuel pumps. By following these precautions and working carefully, you can help ensure a safe and successful fuel pump replacement or installation.

When to replace a fuel pump

The fuel pump is an essential component of your vehicle, delivering gas or diesel to the engine's combustion chamber. Usually, fuel pumps last for many years without any issues. However, there are certain warning signs that indicate it's time to replace your fuel pump.

Warning Signs

• Inability to Maintain Speed: You may feel like your engine is "choking" or struggling to maintain speed, even though your fuel gauge shows there is enough gas in the tank.
• Engine Overheating: A failing fuel pump may overheat, causing the engine to overheat as well. The vehicle may operate for 15-30 minutes before stopping due to overheating.
• Sputtering and Stalling: Noises, backfires, and sputtering engines are common symptoms of a failing fuel pump. Electronic fuel pumps typically don't make noise unless they start to fail.
• Engine Light Comes On: The "Check Engine" light on your dashboard may illuminate, indicating a potential issue with the fuel pump.
• Loss of Power: You may experience a sudden loss of power while driving, such as when going up a steep hill. This indicates that the fuel pump is not transferring enough fuel to the engine.
• Engine Surging: A failing fuel pump can send too much fuel to the engine, causing the vehicle to surge, which is when it picks up and then drops speed.
• Decreased Gas Mileage: If the fuel pump is sending too much fuel to the engine or the relief valve is not functioning properly, you may notice a decrease in your vehicle's gas mileage.
• Dead Engine: In some cases, the fuel pump may get clogged or fail completely, resulting in a dead engine that won't start at all.

It's important to note that vehicles can sometimes continue to run for a short distance or period even with a malfunctioning fuel pump. However, driving with a faulty fuel pump can cause premature wear and tear on your engine and reduce the value of your vehicle. Therefore, it's recommended to have your car inspected as soon as you notice any of the above symptoms.

Fuel pump replacement cost

The cost of replacing a fuel pump will depend on the make and model of your vehicle, and where you choose to have it fixed. According to RepairPal.com, the average fuel pump replacement cost is between $834 and $874, with about 80% of the cost being the price of parts. However, some sources state that the average cost can be as high as between $1,148 and $1,321.

Labor costs for fuel pump replacement are estimated to be between $150 and $350, while parts can cost between $50 and $1,110. More expensive vehicles with complex designs may cost up to $2,500 to have a fuel pump replaced.

It is recommended that fuel filters are replaced at the same time as the fuel pump, and on some vehicles, the fuel pump relay is known to fail, so it is good practice to replace the relay when the pump is replaced.

Fuel pump replacement preparation

Before attempting to replace your electric fuel pump, there are several steps you should take to ensure the process goes smoothly and safely. Here is a detailed guide on how to prepare for the replacement:

Firstly, ensure you have the correct replacement pump for your vehicle. Many pumps appear similar but may have different flow rates and pressure ratings. Some vehicles may require you to provide the engine VIN code to look up the correct pump. It is also recommended to buy a name-brand pump rather than a cheap, low-quality one, as the latter has a reputation for poor quality and durability.

Next, gather all the necessary tools and safety equipment. This includes a new fuel pump, fuel filter, and any other components specific to your vehicle. Ensure you have a safe and accessible workspace, and take proper safety precautions. Pull the fuel pump relay and disconnect the battery. Consult your vehicle's service manual or online tutorials for additional guidance and to familiarize yourself with the process.

If your fuel pump is located inside the fuel tank, as is common in most vehicles with electronic fuel injection, you will need to reduce the amount of fuel in the tank. This will make the tank lighter and easier to handle, and reduce the risk of spillage during the replacement process. Use a hand siphon pump to drain the tank, and store the fuel in an approved container.

Now, you will need to jack up your car and support it with axle stands. Never work under a vehicle supported only by a hydraulic jack. Disconnect the filler neck from the fuel tank by loosening or removing the clamp that holds the hose on the tank.

Finally, before unbolting the straps that secure the fuel tank, remove the remaining fuel. Then, remove the bolts securing the fuel tank straps to the vehicle, and gently lower one end of the tank. This will allow you to access the wiring connections, fuel line, and vent hoses on top of the tank. Disconnect these before removing the remaining bolts and lowering the tank from the vehicle.

With these preparation steps completed, you can now proceed to replace the fuel pump, following the instructions specific to your vehicle.

Fuel pump reassembly

First, reassemble the fuel system and test the new fuel pump to ensure that everything is functioning properly. Reconnect the EVAP system vapor hoses to the fuel tank, and the fuel line to the fuel pump outlet. Make sure all hoses are correctly routed.

Next, raise the fuel tank back into place and reinstall the support straps that hold it in place. Reconnect the fuel filler hose to the fuel tank inlet. Make sure all clamps are tight.

Add several gallons of fuel to the tank and check for leaks. The tank should be at least 1/4 full to provide enough fuel for proper fuel pump lubrication and cooling before starting the vehicle.

Finally, install a new fuel filter in the fuel supply line. Do not reuse the old in-line fuel filter as it may be dirty and restrict fuel flow to the engine. Start the engine and check all fuel line connections for leaks.

Some additional tips for replacing a fuel pump include:

• Working in a well-ventilated area to minimize the risk of fire or inhaling harmful fumes.
• Using proper safety gear such as safety glasses, gloves, and appropriate clothing to protect against fuel spills and splashes.
• Draining or siphoning out most of the fuel from the tank to reduce the risk of spills and make the fuel tank lighter and easier to handle.
• Cleaning around the fuel pump to prevent dirt and debris from falling into the fuel tank.
• Replacing fuel pump components such as the fuel filter, fuel pump strainer, and fuel tank O-ring or gasket.

Frequently asked questions