Replacing The Fuel Pump In A Classic: Step-By-Step Guide

Changing the fuel pump on a 1996 vehicle is a moderately complicated job that is best performed at a dealership's service department. However, it is possible to change the fuel pump yourself. This can be done in 1.5 hours by cutting a hole in the package shelf to change out the pump. Alternatively, you can follow the official instructions, which involve dropping everything under the back of the car so that you can remove the tank, which will take most of a day.

Disconnect the negative battery cable

Disconnecting the negative battery cable is a crucial step when changing the fuel pump on a 1996 Buick Regal. This procedure is standard for any repairs or maintenance work done on a vehicle.

The negative battery terminal, also known as the ground strap or cable, is directly connected to the vehicle's engine, body, and chassis. Disconnecting it first before the positive terminal is essential for safety reasons and to prevent damage to electrical components.

If you were to remove the positive terminal first, it could touch the chassis or engine through a metal tool, creating a short circuit. This could lead to fire and physical injury. By disconnecting the negative terminal first, you eliminate the risk of an accidental short circuit.

How to Disconnect the Negative Battery Cable

• Make sure the engine is turned off.
• Locate the battery. It is usually under the hood but may be in the trunk, so always consult your owner's manual to determine the correct location.
• Identify the battery terminals. The negative terminal is typically denoted by a "-" symbol and may have a black cable connected to it.
• Using a wrench, loosen the nut on the negative terminal and remove it from the battery post. Ensure that the cable is kept away from the terminals.
• After confirming that the negative cable is secure and cannot touch the terminals, proceed to remove the nut on the positive terminal.

By following these steps, you can safely disconnect the negative battery cable, ensuring that you minimise the risk of any accidents or damage during your fuel pump replacement.

Drain the fuel tank

To drain the fuel tank of a 1996 Buick Regal, first remove the fuel filler cap to vent any pressure in the tank. Then, remove the fuel pump fuse from the fuse box, start the engine, and run it until it dies. Turn the engine over with the key for three seconds, then turn it off.

Next, disconnect the negative battery cable with a wrench, and siphon as much fuel from the tank as possible with a siphon kit. Chock the front wheels with wood blocks, then raise the rear of the vehicle with a jack and support it with jack stands.

Now, disconnect the connector block for the fuel gauge sending unit and the fuel pump power supply located at the front of the tank. Do this by hand. Disconnect the filler neck, vent, fuel feed, fuel return, and fuel vapour tubes from the tank. Squeeze the tabs on the plastic retainer clip by hand and pull the lines off. Loosen the pressure fittings with a flare nut wrench and a backup wrench.

Inspect the o-ring on the pressure fitting and replace it if necessary. You can now remove the fuel tank.

This process will vary depending on the specific make and model of the car.

Disconnect the fuel pump power supply

To disconnect the fuel pump power supply on a 1996 Buick Regal, follow these steps:

Firstly, remove the fuel filler cap to vent any pressure in the tank. Then, remove the fuel pump fuse from the fuse box. Start the engine and let it run until it dies. Turn the engine over with the key for three seconds, then turn it off.

Now, disconnect the negative battery cable with a wrench. Siphon as much fuel as possible from the tank using a siphon kit. Chock the front wheels with wood blocks. Next, raise the rear of the vehicle with a jack and support it with jack stands.

Finally, disconnect the connector block for the fuel gauge sending unit and the fuel pump power supply, which is located at the front of the tank. This can be done by hand.

Remove the fuel tank

To remove the fuel tank from a 1996 vehicle, you will need to take the following steps:

Firstly, remove the fuel filler cap to vent any pressure in the tank. Then, remove the fuel pump fuse from the fuse box. Start the engine and let it run until it dies. Turn the engine over with the key for three seconds, then turn it off.

Next, disconnect the negative battery cable with a wrench. It is important to siphon as much fuel from the tank as possible using a siphon kit. Chock the front wheels with wood blocks and raise the rear of the vehicle with a jack. Support the vehicle with jack stands.

Now, disconnect the connector block for the fuel gauge sending unit and the fuel pump power supply, located at the front of the tank. You can do this by hand. Disconnect the filler neck, vent, fuel feed, fuel return, and fuel vapor tubes from the tank. Squeeze the tabs on the plastic retainer clip by hand and pull the lines off. Loosen the pressure fittings with a flare nut wrench and a backup wrench. Inspect the o-ring on the pressure fitting and replace it if necessary.

At this point, you may need to remove the rubber exhaust hangers and the exhaust pipe and heat shield with wrenches. Now, remove both fuel tank retaining straps with a wrench. Carefully lower the fuel tank away from the vehicle.

Note: It is important to work with caution when handling the fuel system. Gasoline is extremely volatile, and the fumes are explosive. Ensure you perform this work outside or in a well-ventilated area. Do not work on the fuel system in an enclosed building with natural gas fixtures, as the pilot light may cause an explosion.

Additionally, if your vehicle is equipped with an anti-theft system, be sure to disable the lockout feature before disconnecting the battery cable.

Remove the old fuel pump

To remove the old fuel pump from your 1996 vehicle, you will need to first ensure the vehicle is safe to work on. This includes removing the fuel filler cap to vent any pressure in the tank, disconnecting the negative battery cable, and siphoning as much fuel from the tank as possible. You will also need to chock the front wheels and jack up the rear of the vehicle, supporting it with jack stands.

Next, you will need to disconnect various components connected to the fuel tank. This includes the connector block for the fuel gauge sending unit and the fuel pump power supply, as well as the filler neck, vent, fuel feed, fuel return, and fuel vapor tubes. You may also need to remove the rubber exhaust hangers, exhaust pipe, and heat shield, depending on your vehicle model.

Once these components are disconnected, you can then remove the fuel tank retaining straps and carefully lower the fuel tank away from the vehicle. Be cautious when handling the fuel level float and sending unit as they are delicate and easily damaged.

Now that you have access to the fuel pump, you will need to unlock the fuel pump from the fuel tank. This typically involves tapping on the tabs of the lock ring with a punch and a hammer, rotating the ring counterclockwise until the tabs align with the slots in the fuel tank. Once the lock ring is disengaged, lift the pump up and out of the tank.

Before installing the new fuel pump, be sure to inspect the rubber sealing ring around the locking mechanism and replace it if necessary.

Frequently asked questions