Replacing The Fuel Pump In Your Ef Falcon: Step-By-Step Guide

Replacing the fuel pump on an EF Falcon can be a tricky task. The pump is located at the top of the fuel tank, which means you will need to empty the tank before accessing it. The pump is held in place by a locking ring, which can be challenging to remove without breaking. Once the locking ring is off, you can disconnect the fuel lines and lift out the pump assembly. When installing the new pump, make sure the filter sock sits properly in the tank. It is also recommended to replace the seal around the tank, as it may have deteriorated over time.

Removing the boot carpet and cover plate

To remove the boot carpet and cover plate of your EF Falcon, follow these steps:

First, lift the boot carpet to access the cover plate underneath. You will need to unscrew the screws holding the cover plate in place. In most EF Falcon models, there are six screws that need to be removed. However, the number of screws may vary depending on the year and model of your EF Falcon.

Once the screws are removed, carefully lift and remove the cover plate. It is important to be gentle during this process to avoid damaging any surrounding components or the cover plate itself. Place the cover plate aside in a safe location to avoid misplacing or damaging it during the fuel pump replacement process.

With the cover plate removed, you will now have access to the fuel pump assembly. Before proceeding, it is recommended to mark the fuel lines with a pen or tape to ensure proper reconnection during the reinstallation process. Additionally, some EF Falcon models may have a jubilee clip around the locking ring, which should be unscrewed and removed before proceeding.

Now, you can focus on removing the locking ring that secures the fuel pump assembly. This process can be challenging, and you may need to use a hammer and a suitable tool, such as a large screwdriver or a specialised fuel pump retaining ring removal tool, to carefully tap the locking ring in an anti-clockwise direction to loosen and remove it. Be cautious not to break the ribs of the locking ring during this process.

Once the locking ring is removed, you can proceed with disconnecting the fuel lines and unplugging the electrical connections to the fuel pump. Again, marking the fuel lines beforehand will ensure proper reassembly. With the fuel lines and electrical connections disconnected, you can now carefully lift and remove the entire fuel pump assembly from the vehicle.

Disconnecting hoses and marking which is which

Disconnecting the hoses and marking which is which is a crucial step in replacing the fuel pump in an EF Falcon. Here is a detailed guide on how to approach this task:

Firstly, locate the pump by removing the boot carpet and unscrewing the cover plate on the passenger side of the boot floor. You should see the two hoses connected to the pump. Before disconnecting them, it is important to mark which hose is which to ensure proper reassembly. Use a pen or a marker that petrol will not wash off easily to label the hoses. This will make it clear which hose goes where when you are reconnecting them later.

Once the hoses are labelled, you can carefully pull them off the pump. It is important to be gentle during this step to avoid any damage to the hoses or the pump. After disconnecting the hoses, set them aside in a safe place to avoid any confusion during reassembly.

If your EF Falcon has a jubilee clip around the locking ring, now would be the time to unscrew and remove it. Theoretically, the locking ring should now unscrew easily. However, in some cases, you may need to use a hammer and a screwdriver or a similar tool to help loosen it. Be careful not to break off the ribs as you are bashing and unscrewing the locking ring.

With the locking ring removed, you should now have access to the fuel pump. You can unplug and remove the old pump, being mindful of any remaining fuel in the tank and lines. If you are encountering any issues with removing the locking ring or the pump itself, it may be necessary to partially cut or grind the ring to gain better access.

Overall, this process requires careful labelling of the hoses, gentle removal of the hoses and locking ring, and patience during the removal of the fuel pump. Taking your time and following these steps will help ensure a successful fuel pump replacement in your EF Falcon.

Removing the locking ring

To remove the locking ring, you will need to break the seal and start draining the fuel tank into a clean pan. You will need to jack up the passenger side of the car so the fuel runs to the opposite side of the tank. Then, remove the ring and both fuel lines by simply clipping them off. The pump assembly should come out, but it is a little difficult to get out, so be careful not to break anything. You will need to angle it to the left and gently pull it through.

The locking ring can be tight, so you may need to use a wooden dowel and a mallet to bang the screw ring open in an anti-clockwise direction. If you are handy with making homemade tools, you can make a fuel pump retaining ring removal tool out of aluminium.

If you are still having trouble getting the locking ring off, be careful not to break off too many of the lips. You can also try using a hammer and some sort of drift, like a big screwdriver, to bash and curse at it. If it's still too difficult, you can cut off the locking ring with an angle grinder.

Unplugging the pump and removing it

To unplug and remove the fuel pump from your EF Falcon, follow these steps:

First, locate the fuel pump. In an EF Falcon wagon, the fuel pump is behind the left-hand rear wheel and enters the tank through the side. In a sedan, remove the boot carpet and unscrew the cover plate on the passenger side of the boot floor to access the pump.

Before removing the fuel pump, you will need to relieve the fuel pressure and drain the fuel tank. Jack up the passenger side of the car so that the fuel runs to the opposite side of the tank. Be very careful when handling petrol.

Once the tank is drained, you can proceed to remove the fuel pump. If there is a jubilee clip around the locking ring, unscrew and remove it. Now, try to unscrew the locking ring. If it's too difficult to unscrew by hand, you may need to use a hammer and a screwdriver to gently tap it loose. Be careful not to break off the ribs as you tap it. If it's still too difficult, you can use an angle grinder to remove some of the top flap over the metal of the pump assembly, then use the screwdriver to split the rest, being careful of the threads.

After removing the locking ring, unplug the pump. There may be a clip holding the pump in place, so use two small screwdrivers or a similar tool to unclip the fuel lines. Lift out the entire housing, being careful not to damage any components.

Now, you can install the new fuel pump by following the reverse steps. Make sure to check for leaks once the new pump is installed.

Installing the new pump and reconnecting the hoses

Now that you have removed the old pump, it is time to install the new one. Place the new pump into the tank, ensuring that the filter sock sits properly inside the tank. If you are using a new housing, you will need to secure the pump with a cable tie or hose clamp.

Next, reconnect the fuel lines. This can be done by pushing the white thing down and pulling the lines off. If you are having trouble with this step, you may need to purchase a fuel line removal tool. Once the lines are reconnected, lower the tank back into place and secure it with the straps.

Finally, reverse the steps you took to access the pump in order to reassemble the car. This includes replacing the carpet and screws, as well as reconnecting the negative battery terminal. Be sure to check for leaks before starting the car.

Frequently asked questions