Switching Fuel Pumps: Intank To Manual, Easy Steps

Changing a fuel pump can be a difficult job, so caution and prior research are advised. It is important to first rule out other potential issues, such as a broken gas line, clogged filter, or electrical problem. If the fuel pump is definitely faulty, there are several steps to replacing it. First, drain the fuel tank and disconnect the filler neck from the tank. Then, remove the bolts securing the fuel tank straps to the vehicle and disconnect the wiring connections, fuel line, and vent hoses. At this point, the fuel pump can be removed and replaced with a new one. It is recommended to replace the whole fuel pump module assembly, rather than just the pump itself, to make installation easier and reduce potential future issues. When installing the new pump, ensure that all connections are secure and tight, and check for leaks before starting the engine.

Jack up your car and drain the tank

Jacking up your car and draining the tank is a crucial step in changing from an in-tank fuel pump to a manual pump. Here is a detailed, step-by-step guide to help you with this process:

Park Your Vehicle in a Safe Area:

• Choose a sturdy, level surface, such as concrete or asphalt, to park your car. Avoid soft or uneven terrain, as it can be dangerous if the ground shifts or the jack moves unexpectedly.
• Engage the parking brake and put the transmission in park for automatic vehicles or first gear for manual transmissions.
• Place chocks or wheel wedges behind the wheels on the opposite side of the car from where you plan to jack it up. This will prevent the car from accidentally rolling.

Locate the Jack Points:

• Refer to your vehicle's owner's manual to find the designated jack points. These are reinforced areas designed to bear the weight of the vehicle safely.
• There are typically jack points near each wheel, and sometimes additional ones between the front and rear wheels.
• Look for flat metal areas, notches, cutouts, or sturdy plastic blocks attached to the frame.

Position and Operate the Jack:

• Place the jack under a chosen jack point, ensuring the wide, flat base is facing down.
• Raise the jack by turning or pumping the lever until it touches the car. Keep going until the nearest wheel is lifted off the ground.
• For common tasks like draining the tank, a lift of 3 to 6 inches (7.6 to 15.2 cm) should be sufficient.
• If you need to work under the car, insert a jack stand next to the jack. Raise the stand until it touches the jack point, then slowly lower the car onto it.

Drain the Fuel Tank:

• Before unbolting the fuel tank straps, remove as much fuel as possible from the tank. This will make it lighter and easier to handle.
• If your tank has a drain plug, use it to drain the fuel. Otherwise, use a hand siphon pump to draw the fuel out.
• Insert the siphon hose down the filler neck and use the pump to start the siphon action.
• Drain the fuel into an approved container, such as a metal or plastic gas can. Do not use open buckets.
• Seal the container once the tank is empty, and store it safely away from open flames or sparks.

Remember to exercise extreme caution when working with gasoline. Ensure proper ventilation, keep away from ignition sources, and have a fire extinguisher nearby.

Disconnect the filler neck from the fuel tank

Disconnecting the filler neck from the fuel tank is a crucial step in changing from an in-tank fuel pump to a manual pump. Here is a detailed, step-by-step guide on how to safely and effectively complete this task:

Before beginning any work on your vehicle, it is essential to take necessary safety precautions. Ensure you are working in a well-ventilated area, keep cigarettes and open flames away, and have a fire extinguisher nearby. Additionally, wear safety goggles and gloves for protection.

Now, let's begin with the first step:

• Park your vehicle on a level surface and engage the parking brake. This will prevent the vehicle from moving during the process. It is also recommended to block the front wheels for added safety.
• Jack up the rear of the vehicle. Place a minimum of two jack stands with the proper weight rating to support the vehicle securely. Do not work under the vehicle if it is only supported by a jack.
• Locate the filler neck and the fuel tank. The filler neck is the component that connects the fuel filler port to the fuel tank, allowing fuel to enter the tank when filling up.
• Identify the hose that connects the filler neck to the fuel tank. This hose will need to be carefully removed.
• Loosen or remove the clamp that holds the hose on the tank. This will involve using the appropriate tools, such as wrenches or screwdrivers, to loosen or remove the clamp without damaging the surrounding components.
• Once the clamp is loosened or removed, carefully pull the hose off the filler neck. You may need to twist or wiggle the hose gently to detach it. Be cautious not to spill any fuel during this step.
• After disconnecting the hose, you will need to plug the end of the hose to prevent any fuel leaks. Use a suitable object, such as a dowel or bolt, to seal the opening.
• With the hose disconnected and plugged, you can now proceed with the rest of the process of changing the fuel pump. This may involve lowering the fuel tank further, disconnecting additional hoses and wiring, and removing the old fuel pump.

Remember to work cautiously and refer to vehicle-specific repair manuals or seek professional assistance if needed. Working with fuel systems can be dangerous, so taking your time and following safety protocols is crucial.

Remove bolts and lower the tank

Before removing the bolts and lowering the tank, you will need to drain the fuel tank. Siphon off the majority of the fuel and store it in several 20-litre containers with screw-capped lids for safe storage. Place a drainage container under the tank and unscrew the filler hose clip, easing the rubber pipe off to allow the remaining fuel to drain.

Now, you can start to remove the bolts. The number of bolts will vary depending on the vehicle, but typically, there are two bolts at the front and two at the rear of the tank. First, remove the exhaust heat shield and pull the handbrake cables out of their holders. Then, remove the wiring and pipe clips, and the filler hose. Place the drainage container back under the bottom hose coupling.

Remove all the bolts and ease the tank towards the filler end, pulling and raising the far end with your foot so it can be carefully eased out and lowered. Be careful not to kink any pipes. Once the tank is lowered, the wiring connector and the two fuel pipes can be removed.

Disconnect wires, hoses, and pipes

Disconnecting the wires, hoses, and pipes from your fuel tank is a crucial step in changing from an in-tank fuel pump to a manual pump. Here's a detailed guide on how to do it safely and effectively:

Parking and Safety Precautions:

Before beginning any work on your vehicle, it's important to take the necessary safety precautions. Park your vehicle on a level surface and set the parking brake. Ensure that the transmission or transaxle is in park (in gear if it's a manual transmission). Block the front wheels to prevent the vehicle from rolling. Additionally, always use axle stands or ramps under the wheels when working under the vehicle. Never rely solely on a hydraulic jack to support the car.

Disconnecting the Ground Cable:

Locate the ground cable, usually black, connected to the battery's negative (-) terminal. Disconnect this cable before proceeding with any other steps.

Disconnecting the Filler Neck:

Locate the clamp that holds the filler neck hose on the fuel tank. Loosen or remove this clamp to disconnect the filler neck from the tank.

Loosening Fuel Tank Bolts and Disconnecting Wires and Hoses:

Depending on the vehicle, you may need to remove either the front two bolts or the rear two bolts that secure the fuel tank straps. Gently lower one end of the tank to access the wiring connections, fuel line, and vent hoses on top of the tank. Disconnect all wires and hoses before removing the remaining bolts that hold the other end of the straps.

Releasing Tank Pressure:

Refer to your car's service manual for instructions on how to safely release the gas tank pressure. This step is crucial to avoid any accidental spills or injuries.

Disconnecting the Fuel Tank Hose and Vapor Return Hose:

Loosen the clamp connecting the fuel tank hose and the vapor return hose (if present) to the old fuel pump. Carefully disconnect the hose(s) from the pump. It's important to plug the end of the disconnected hose with a dowel or bolt to prevent any fuel spills.

Disconnecting the Fuel Outlet Line:

To disconnect the fuel outlet line going to the carburetor, grasp the fuel pump fitting firmly with one wrench while unscrewing the nut with another wrench. This step may require some force, but be careful not to damage any nearby components.

Unscrewing Fastening Bolts:

After disconnecting all the hoses and wires, locate the fastening bolts that secure the fuel pump in place. Unscrew these bolts, and you can now discard the old fuel pump.

Final Checks:

Before removing the fuel tank completely, ensure that all wires, hoses, and pipes are properly disconnected. Double-check for any remaining connections to avoid any accidental damage when removing the tank.

By following these steps, you can safely and effectively disconnect the wires, hoses, and pipes from your fuel tank, preparing you for the next steps in changing from an in-tank fuel pump to a manual pump. Remember to stay organized and keep track of the disconnected components to make reassembly easier.

Install the new pump and reconnect

Now that you've drained the tank, removed the old pump, and purchased a new one, it's time to install the new pump and reconnect the system.

First, make sure you have the correct replacement fuel pump for your vehicle. Many pumps appear similar on the outside but may have different flow rates and pressure ratings. Some applications, such as GM Flex Fuel vehicles, may require the engine VIN code in addition to the year, make, and model to look up the correct replacement pump. It is also recommended to buy a name-brand pump and to replace the whole fuel pump module assembly rather than just the pump itself, as this makes installation easier and reduces potential for future issues.

Next, install the new pump into the tank. Put a new filter screen on the pump (this usually comes with the pump) and install a new gasket or seal on the top plate to prevent leaks. If you are replacing the entire fuel pump module assembly, it will come with a new inlet filter screen and fuel level sending unit.

Once the new pump is installed, reconnect the wiring harness to the pump, making sure all the connectors are clean and tight. You can use dielectric grease on the connectors to keep out moisture and prevent corrosion. 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.

Now, 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 and ensure all clamps are tight.

Finally, 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 pump lubrication and cooling before starting the vehicle. Install a new fuel filter in the fuel supply line – do not reuse the old in-line fuel filter as it may restrict fuel flow to the engine. Start the engine and check all fuel line connections for leaks. If there are no leaks, you're done!

Frequently asked questions