Replacing Honda Sh150 Fuel Pump: Step-By-Step Guide

If your Honda SH150 fuel pump is acting up, you may need to replace it. This is a job you can do at home with basic tools, and you won't even need to remove the fuel tank. You will need to remove the rear seat, the bracket, and the cap to access the fuel pump and fuel level sensor. You will also need to remove the electrical connections and fuel lines, and then the pump assembly itself. It's important to be careful and not crack the plastic when removing and reinstalling parts. Finally, you will need to install a new pump, making sure to position it correctly inside the gas tank.

Removing the rear seat

To replace the fuel pump of a Honda SH150, you will first need to remove the rear seat. Here is a detailed, step-by-step guide on how to do this:

• Fold the rear seat forward to access the carpet.
• Remove the carpet to expose the fuel pump cover and wiring harness.
• Disconnect the electrical connector and any other necessary wiring from the fuel pump.
• Lift and remove the rear seat entirely, providing clear access to the fuel pump assembly.

It is important to note that the process of removing the rear seat may vary slightly depending on the specific model and year of your Honda SH150. Ensure you have the correct tools and safety equipment before proceeding with any maintenance or repair work.

Once the rear seat is removed, you can proceed with the next steps to replace the fuel pump, including draining the fuel tank, disconnecting fuel lines, and accessing the pump for removal and replacement.

Disconnecting the fuel lines

Before beginning, ensure you have gathered the necessary tools and safety equipment, including a jack, jack stands, a hydraulic jack, a long piece of wood, and a 10mm socket. It is also recommended to have a vacuum pump or tube to siphon the gas from the tank.

Now, let's get started:

• Remove the rear seat: This will grant you access to the fuel pump and fuel level sensor. Be careful when handling the seat to avoid any damage.
• Disconnect electrical connections: There are two connections to disconnect. One is for the fuel pump, and the other is for the fuel gauge sensor. It is important to start your car to relieve any pressure remaining in the line, but be sure to do this with the sensor disconnected.
• Remove the fuel lines: There will be two fuel lines that you need to remove. They are typically secured with clip connections, so be prepared to use some muscle to detach them safely. Remember to place a rag near the connections to catch any fuel that may spill.
• Prepare for fuel spillage: Place an old towel or a similar absorbent material underneath the vehicle to catch any leftover fuel that may drip out during the process.
• Access the fuel pump: To do this, you will first need to remove the rear left wheel. Once the wheel is off, you will have access to the fuel lines and the fuel pump itself.
• Identify the different fuel lines: There should be four fuel lines in total. Two hard lines, including a brass line that connects directly to the tank and a high-pressure line. Additionally, there is a large line for fuel input.
• Disconnect the fuel lines: Carefully detach each of the four fuel lines, ensuring that you do not damage the connections or the lines themselves.

By following these steps, you will have successfully disconnected the fuel lines, bringing you one step closer to completing the fuel pump replacement in your Honda SH150. Remember to stay safe and take your time during the process.

Removing the fuel pump

To remove the fuel pump from a Honda SH150, you will first need to remove the rear seat. Then, remove the bracket (sub-frame). Next, remove the cap to gain access to the fuel pump and fuel level sensor.

Disconnect the electrical connections—there are two. One is for the pump, and the other is for the fuel gauge sensor. Start your car to relieve any pressure left in the line, but make sure you do this with the sensor disconnected. Move everything out of the way so you can easily access the pump.

Now, remove the two fuel lines. These are just clip connections, so they come off fairly easily. Remember to put a rag close to the connections to catch any fuel.

Take the 10mm nuts off the pump cover (there are approximately six). Then, remove the pump assembly from the tank and bring it to a working area. Remember to put down an old towel to catch any leftover fuel.

There is a small washer retainer that holds the filter to the bottom of the pump. Remove it with a screwdriver and discard it—your new pump will supply you with a new one. After taking the filter off, disconnect the coupling hose from the hard line to the pump, and then disconnect the electrical connection. Make sure you keep the rubber gasket at the bottom of the pump, as you will need to reuse this.

Installing the new pump

To install the new pump, mount it to its holder and position it correctly inside the gas tank. There is a small plastic container inside the tank where the fuel pick-up is located. Make sure the pump sits inside this container.

Next, raise the tank and secure the straps. Reconnect all the fuel lines, ensuring the high-pressure line is tightened. Put the wheel back on and lower the vehicle.

Now, pour some fuel into the tank and turn the key to prime the new pump. You can start the car when you can no longer hear the pump priming. Check for leaks. If there are no leaks, put everything back together.

Reconnecting the fuel lines

Now that you have removed the old fuel pump and installed the new one, it's time to reconnect the fuel lines.

First, reconnect the two fuel lines that were disconnected earlier. These are just clip connections, so they should be fairly easy to snap back into place. Make sure you have a rag or towel nearby to catch any remaining fuel.

Next, reconnect the electrical connections. There are two of these: one for the pump and one for the fuel gauge sensor. Ensure that these are securely connected before proceeding.

Once the fuel lines and electrical connections are reconnected, it's time to put everything back into place. Start by placing the pump assembly back into the tank. Make sure that the filter sits correctly into the baffle. Tighten the bolts of the pump cover to the specified torque (refer to your Honda SH150 manual or a mechanic for this information).

Now, you can mount the fuel tank back into position and reconnect the fuel-sending unit. Secure the tank straps and ensure that all fuel lines are properly connected, especially the high-pressure line.

Finally, you can put the rear wheel back on and lower the vehicle. Open the gas cap and add some fuel. Start the engine and listen for any unusual noises. Check for leaks and, if everything looks good, put the rear seat back into place.

You have now successfully replaced the fuel pump on your Honda SH150!

Frequently asked questions