Replacing Fuel Pump In Your Vy Ute: Step-By-Step Guide

If you're experiencing issues with your Holden VY Ute's fuel pump, you may need to replace it. While there are some online resources, such as YouTube videos and forum discussions, that can provide guidance on how to change the fuel pump, it's important to approach this complex task with caution. The process may involve removing the tank, disconnecting various components, and accessing the pump from underneath the vehicle. It is recommended to seek assistance from a qualified mechanic or automotive technician to ensure a safe and effective fuel pump replacement.

Removing the tub liner vs dropping the tank out

Overview

The process of changing a fuel pump on a Holden VY Ute can be challenging and time-consuming. There are two main approaches to accessing the fuel pump: removing the tub liner or dropping the tank out. Each method has its own advantages and considerations, which will be outlined in detail below.

Removing the Tub Liner

One approach to changing the fuel pump on a VY Ute is to remove the tub liner. This method can be more straightforward and may not require lowering the vehicle or extensive disassembly. However, it is important to note that accessing the pump from the tray may not be possible in all cases. Here are the key steps and considerations for this method:

• Assess the accessibility of the pump: Before starting, it is crucial to determine if the fuel pump can be reached from the tray. In some cases, there may be no access to the pump from the tray, requiring the tank to be dropped out.
• Remove the tub liner: If access is possible, start by removing the tub liner. This will provide better access to the fuel pump and its components.
• Disconnect relevant components: Depending on the vehicle's configuration, you may need to disconnect the exhaust, heat shield, tailshaft, handbrake cables, fuel filler, breather, fuel lines, and other relevant components to create more workspace and access the fuel pump.
• Check pump power: If you suspect a faulty fuel pump, it is recommended to check the pump power at the main connector. This can be done by disconnecting the connector and using a multimeter to check for voltage.

Dropping the Tank Out

Another approach is to drop the fuel tank out, providing direct access to the fuel pump. While this method may be more involved, it ensures better access to the pump and can make the replacement process easier. Here are the key steps and considerations for this method:

• Prepare the workspace: Ensure you have a safe and level workspace with adequate clearance. You may need to use jack stands and a floor jack to raise the vehicle and gain access to the fuel tank.
• Drain the fuel tank: Before starting, it is essential to drain as much fuel as possible from the tank. This can be done by running the vehicle until the tank is close to empty or by siphoning the fuel into another vehicle or container.
• Disconnect relevant components: Similar to the previous method, you will need to disconnect various components to access the fuel tank and fuel pump. This may include the exhaust, heat shield, tailshaft, handbrake cables, fuel filler, breather, fuel lines, and other relevant items.
• Lower the fuel tank: Once the necessary components are disconnected, carefully lower the fuel tank using a jack or appropriate support. Ensure you have adequate clearance underneath the vehicle to accommodate the tank.
• Access and replace the fuel pump: With the tank lowered, you can now access the fuel pump for inspection or replacement. Follow the appropriate procedures to remove and replace the fuel pump, ensuring all connections are secure and properly sealed.
• Reinstall the fuel tank: After completing the necessary repairs or replacements, carefully reinstall the fuel tank and reconnect all the relevant components. Ensure all connections are secure and properly tightened.

Comparison

Both methods have their advantages and considerations. Removing the tub liner may be faster and less involved, but it depends on the accessibility of the fuel pump from the tray. Dropping the tank out provides direct access to the fuel pump but may require more time and effort. Ultimately, the chosen method will depend on the specific vehicle, the accessibility of the fuel pump, and the comfort level of the person performing the repair.

Disconnecting the fuel filler and breather

First, locate the fuel filler and breather. These are usually found behind the driver's side wheel arch liner. You will need to remove the wheel arch liner to access them. Make sure you have the necessary tools, such as a socket wrench and screwdrivers, before beginning. Once you have located the fuel filler and breather, you can start the disconnection process.

To disconnect the fuel filler, you will need to remove any clamps or hoses that are attached to it. Be careful when removing these, as they may be tight. You may also need to remove any clips or fasteners that are holding the fuel filler in place. Once all the connections are removed, carefully lift the fuel filler out of its housing.

The breather hose is usually connected to the fuel tank. To disconnect it, first locate the hose and follow it to the connection point on the fuel tank. There may be a clamp or hose clip holding it in place. Carefully loosen and remove the clamp or clip, then detach the breather hose from the fuel tank. Make sure to have a container ready to catch any fuel that may spill during this process.

It is important to label or mark the hoses and connections to ensure proper reassembly. You can use tape and a marker to label them accordingly. This will make it easier when it's time to put everything back together.

After disconnecting the fuel filler and breather, it is essential to clean the area. This will help prevent any dirt or debris from entering the fuel system. Use a clean cloth or towel to wipe down the area, including the fuel filler housing and the connection point on the fuel tank.

By following these steps, you will successfully disconnect the fuel filler and breather, allowing you to access and replace the fuel pump on your VY Ute. Remember to work carefully and safely, and always refer to a qualified mechanic if you have any doubts or concerns.

Removing the exhaust

To remove the exhaust, you'll need to start by taking the exhaust off from the cats back. This will involve removing the heat shield and tailshaft. You'll then need to disconnect the handbrake cables at the T-junction. This will give you access to the fuel filler and breather, which are located behind the driver's side wheel arch liner. Disconnect these, along with the fuel lines, and then move on to disconnecting the breather at the charcoal canister above the differential.

At this point, you'll be ready to start removing the fuel tank itself. Begin by undoing the front fuel tank strap bolts—you can leave the rears in place and just bend the straps down. Next, loosen the large rear subframe bolts by about 10mm. The front subframe bolts, however, will need to be removed completely. To support the weight of the differential, place a jack underneath and tilt it down enough for the tank to slip out.

Disconnecting the fuel lines

First, locate the fuel lines. These are the hoses that connect the fuel pump to the engine, and they will be secured with clamps or fittings. Before disconnecting anything, make sure you have a container ready to catch any fuel that may spill. Place a drip pan or rag underneath the lines to catch any drips.

Next, you will need to relieve the pressure in the fuel lines. This is an important safety step, as you do not want fuel spraying out or dripping everywhere when you disconnect the lines. To do this, locate the fuse box and remove the fuel pump fuse. Then, turn the ignition key to the "On" position for about two seconds. You should hear the fuel pump running and then stop as the pressure is released.

Now, you can start to disconnect the fuel lines. Using the appropriate tool, loosen the clamps or fittings that secure the fuel lines. Be careful not to damage the lines or the surrounding components. Once the clamps are loose, carefully pull the fuel lines away from the fuel pump. You may need to wiggle them gently to get them free.

With the fuel lines disconnected, you will have easier access to the fuel pump. Be sure to set the lines aside in a safe place, away from any potential sparks or flames. It is also a good idea to plug or cap the open ends of the lines to prevent dirt or debris from getting inside.

Remember to work safely and carefully when dealing with fuel lines, and always refer to a trusted repair manual or mechanic if you are unsure about any steps.

Testing for fuel delivery issues

Check for Basic Issues:

First, it's important to rule out some common basic issues that can cause fuel delivery problems. These include:

• Stale gasoline, often found in private storage tanks, can cause hard starting and poor engine performance.
• E-85 ethanol gasoline, which is intended for flex-fuel vehicles, can cause driveability issues in non-flex fuel vehicles.
• A clogged fuel filter, even in a recently installed one, can impact fuel delivery.
• Defective sensors, such as the mass air flow (MAF), barometric pressure (BARO), throttle position (TP), engine coolant (ECT), or intake air temperature (IAT) sensor, can create symptoms that mimic fuel pump defects.
• A stuck or faulty fuel level sensor can also impact fuel delivery.
• Always ensure the fuel pump is immersed in fuel by adding a few gallons during testing.
• Inspect the fuel tank for any dents or damage that might affect pump operation.

Cranking and No-Start Testing:

When dealing with a suspected fuel pump failure, follow these steps:

• Connect a scan tool to identify the type of fuel delivery system used in your VY Ute. This can provide valuable data such as pulse-width parameters and fuel pressure parameters.
• Poll the various modules for related trouble codes and access bi-directional fuel pump controls.
• Use the scan tool to electronically activate the fuel pump and perform an activation test.
• If the fuel pump doesn't activate, check for an inertia switch installed in series with the fuel pump, which may deactivate the pump during a collision or off-road driving.
• Check for proper voltage and a clean ground at the fuel pump tank connection.

Fuel Trim Numbers and Pressure Testing:

• Record short-term and long-term fuel trim numbers with a scan tool while road-testing the vehicle.
• If short-term fuel trims exceed 20% at wide-open throttle and store specific trouble codes, it indicates a fuel delivery problem.
• However, high positive fuel trims can also be caused by a faulty MAF sensor.
• Calculated engine loads below 80% at wide-open throttle may indicate a dirty or defective MAF or barometric pressure sensor.
• If the calculated engine load exceeds 80%, suspect a fuel delivery issue in the fuel pump, filter, or fuel lines.

Scope Testing:

• Fuel pressure and volume tests may not always accurately diagnose fuel pump issues.
• Using a lab scope is the best way to evaluate the condition of a fuel pump and identify intermittent problems.
• Analyzing the fuel pump waveform can help identify issues with the brushes and/or commutator segments.
• Examining the current waveform of each commutator bar during a complete rotation of the fuel pump will provide an accurate indication of its internal condition.
• The scope also displays average current, which can help identify electrical problems, such as brush and commutator wear, poor ground, or high-resistance connections.

Frequently asked questions