Replacing The Fuel Pump In Your Ve Commodore: Step-By-Step Guide

Replacing the fuel pump on a VE Commodore can be a challenging task, and the process may vary depending on the specific model and year of your vehicle. In some cases, it may be necessary to remove the fuel tank, while in others, access may be possible through an inspection hole or by removing an access panel. Here are the steps to replace the fuel pump in a VE Commodore:

1. Locate the fuel pump: The fuel pump on a VE Commodore is typically located inside the fuel tank.

2. Prepare the vehicle: Park the vehicle on a level surface and engage the parking brake. If necessary, raise the vehicle using a hoist or car stands to access the fuel tank.

3. Drain the fuel tank: Before removing the fuel tank, it is important to drain the fuel to reduce the risk of spillage.

4. Disconnect the fuel lines and electrical connectors: Carefully disconnect the fuel lines and any electrical connectors attached to the fuel pump.

5. Remove the fuel tank: Depending on the model, you may need to remove the exhaust, heat shield, tailshaft, and disconnect the handbrake cables, fuel filler, and breather. Loosen the fuel tank straps and carefully lower the tank.

6. Remove the old fuel pump: With the fuel tank removed, you can now access the fuel pump. Remove any mounting brackets or clamps securing the fuel pump and carefully lift it out of the tank.

7. Install the new fuel pump: Position the new fuel pump in the tank, ensuring it is securely mounted and connected to the fuel lines and electrical connectors.

8. Reinstall the fuel tank: Carefully lift the fuel tank back into position and secure it with the straps. Reconnect all the disconnected components, such as the exhaust, heat shield, and tailshaft.

9. Refill the fuel tank and test: Refill the fuel tank and start the engine to ensure the new fuel pump is functioning properly.

Removing the sender pump MRA unit

To remove the sender pump MRA unit from a VE Commodore, you will first need to determine whether your model has an inspection hole under the rear seat. If there is a circle of sealant on the driver's side, you can access the pump through this hole. If not, you will need to drop the tank.

If you have access to the pump through the inspection hole, use a flat-head screwdriver to peel off the sealant. Then, use a screwdriver to pop off the cover by getting under the edge. You will see a bracket holding the pump module in place; use a hole punch on the bracket and turn it 1/8 to unlock. The fuel line is attached by a clip; hold each side to unclip it from the module and pull it off. When you lift the pump out, there may be a line attached to the bottom that you will need to remove, as well as the fuel line on the top of the module. Be careful with the sender arm, which should face forward.

If you do not have an inspection hole, you will need to remove the tank to access the pump. This is a complex process and may be easier with a hoist. First, remove the exhaust from the catalytic converter (cats) back, as well as the heat shield and the tailshaft. Disconnect the handbrake cables at the T-junction, the fuel filler, and the breather behind the driver's side wheel arch liner. Disconnect the fuel lines and the breather at the charcoal canister above the differential. Undo the front fuel tank strap bolts, leaving the rears in place but bending the straps down. Loosen the large rear subframe bolts, then remove the front subframe bolts completely and support the differential with a jack, tilting it down so that the tank can be slipped out. With the tank removed, you can access the pump and sender unit.

Disconnecting the fuel filler

Firstly, locate the fuel filler and breather behind the driver's side wheel arch liner. This is where you will need to begin the disconnection process. Make sure you have the necessary tools and safety equipment before starting, such as gloves and eye protection. Ensure there are no ignition sources or flames nearby as a precaution.

To disconnect the fuel filler, carefully identify the correct hoses or lines attached to the filler. Typically, there will be fuel lines that need to be detached. Using the appropriate tool, loosen or detach the connections holding the fuel lines in place. Be cautious not to damage the lines themselves, as they are crucial for the proper functioning of the fuel system.

Once the fuel lines are disconnected, you may need to address any clips, clamps, or fasteners that secure the fuel filler in place. Again, use the correct tools to avoid damage and carefully release these securing mechanisms. Depending on the model of your VE Commodore, there may be additional components attached to the fuel filler, such as a breather hose or a vapour hose, that will also need to be carefully disconnected. Ensure that you keep track of the order and orientation of the components as you remove them to facilitate easier reassembly.

After all, connections have been released; you can now carefully lift or move the fuel filler away from its housing. It is important to do this gently to avoid any strain or damage to the attached hoses or lines. Place the fuel filler assembly aside in a safe location, away from any potential hazards.

At this point, you should have successfully disconnected the fuel filler, providing access to the fuel pump for replacement or maintenance. Remember to refer to a qualified mechanic or a detailed repair guide for your specific model if you require further instructions or encounter any issues during the process.

Disconnecting the fuel lines

First, locate the fuel lines. They are connected to the fuel pump module, which is usually accessed by removing the rear seat of the vehicle. Once you have located the fuel lines, you will need to disconnect them from the module. This can be done by holding each side of the connection and unclipping it from the module. There may also be a fuel line attached to the bottom of the pump that will need to be removed in the same manner.

It is important to be cautious when handling fuel lines, as they contain flammable fuel. Ensure that the engine is cool and that there are no sources of ignition nearby. Place a rag or towel underneath the fuel lines to catch any fuel that may spill during the disconnection process.

When disconnecting the fuel lines, gently pull them away from the module. If they are difficult to remove, you may need to use a flat-head screwdriver to carefully pry them loose. Be careful not to damage the lines or the module during this process. Once the fuel lines are disconnected, set them aside, ensuring that they are secure and away from any potential sources of ignition.

In addition to the fuel lines, there may be other connections that need to be disconnected, such as the breather at the charcoal canister above the differential. Refer to your specific vehicle's repair manual for a comprehensive understanding of all the components that need to be disconnected during this process.

Remember to work safely and carefully throughout the entire process of disconnecting the fuel lines. It is important to take your time and ensure that all connections are properly disconnected before proceeding with the next steps of replacing the fuel pump.

Removing the fuel tank

Step 1: Prepare the Vehicle

• Park your vehicle on a level surface and engage the parking brake.
• Make sure you have all the necessary tools and safety equipment, including gloves and eye protection.
• If there is fuel in the tank, drain it or siphon it out to reduce the risk of spillage.

Step 2: Accessing the Fuel Tank

• Locate the fuel tank and identify the fuel lines, hoses, and electrical connections that need to be disconnected.
• Disconnect the exhaust from the catalytic converters (cats) back.
• Remove the heat shield.
• Disconnect the handbrake cables at the T-junction.
• Disconnect the fuel filler and breather behind the driver's side wheel arch liner.
• Disconnect the fuel lines and the breather at the charcoal canister above the differential.

Step 3: Lowering the Fuel Tank

• Undo the front fuel tank strap bolts, and you can leave the rears in place for now.
• Loosen the large rear subframe bolts by about 10mm.
• Remove the front subframe bolts completely and support the differential with a jack, tilting it down enough to create clearance for the fuel tank.

Step 4: Removing the Fuel Tank

• With the differential tilted, carefully remove the fuel tank by sliding it out from under the vehicle.
• Place the fuel tank on a secure surface and proceed to remove the fuel pump.

Note: It is recommended to have a helper assist you during this process, especially when handling the fuel tank and supporting the differential with a jack. Always exercise extreme caution when working with fuel and ensure proper ventilation.

Now that you have successfully removed the fuel tank, you can proceed to replace the fuel pump. Remember to re-install the fuel tank securely and connect all the previously disconnected components before starting the engine.

Replacing the fuel pump

Step 1: Prepare the Vehicle

Before you begin, park the vehicle on a level surface and engage the parking brake. If your Commodore has a solid axle, you will need to lift the rear end slightly to access the fuel pump. Place jack stands under the vehicle for support if necessary.

Step 2: Access the Fuel Pump

To access the fuel pump on a VE Commodore, you will need to remove the fuel tank. Disconnect the exhaust from the catalytic converters (cats) to the rear of the vehicle. Remove the heat shield and the tailshaft. Disconnect the handbrake cables at the T-junction, and disconnect the fuel filler and breather behind the driver's side wheel arch liner. Disconnect the fuel lines and the breather at the charcoal canister above the differential. Loosen the front fuel tank strap bolts and remove the rear strap bolts, then carefully lower the fuel tank.

Step 3: Remove the Old Fuel Pump

With the fuel tank removed, you can now access the fuel pump for replacement. Undo the lock ring and remove the fuel lines and any other connections to the fuel pump. Carefully lift the fuel pump out of the tank, being mindful of the sender arm and any attached lines.

Step 4: Install the New Fuel Pump

Install the new fuel pump by reversing the removal process. Ensure that all connections are secure and that the fuel pump is locked in place. Reinstall the fuel tank by securing it with the straps and reconnecting all the previously disconnected components.

Step 5: Refill and Test

Refill the fuel tank and check for any leaks. Start the engine and allow it to run for a few minutes to build up fuel pressure. Check for any signs of leaks or issues. If the fuel pump was replaced due to low fuel pressure, use a fuel pressure gauge to ensure the pressure is now within the specified range.

Note: Always exercise caution when working with fuel and ensure the area is well-ventilated.

Frequently asked questions