Fuel Pump Replacement: Essential Tools And Components

Replacing a fuel pump can be a challenging task, but with proper precautions, it can be safer and easier. A fuel pump is a small electric motor that transfers fuel from the fuel tank to the engine. The pump creates positive pressure that forces fuel through the gas lines to the engine. The cost of replacing a fuel pump varies depending on the vehicle, age, and region, but typically ranges from $1,000 to $2,000. Before replacing a fuel pump, it is important to gather all the necessary tools and equipment, including a new fuel pump, fuel filter, safety gear, and any other components specific to your vehicle. It is also recommended to reduce the amount of fuel in the tank to minimize the risk of spillage.

Safety precautions

Before attempting to replace a fuel pump, there are several safety precautions you should take to ensure you are working safely and minimising the risk of injury or accident. Here is a list of safety precautions to follow:

• Work in a well-ventilated area, preferably outdoors, to reduce the risk of inhaling harmful fumes and to minimise the risk of fire. Fuel vapours are highly flammable and toxic.
• Wear safety gear, including safety glasses, gloves, and appropriate clothing to protect yourself from fuel spills and splashes.
• Disconnect the negative battery cable to relieve the fuel system pressure.
• Drain the fuel tank or siphon out as much fuel as possible to reduce the risk of spills and make the tank lighter and easier to handle.
• If you are unable to drain the fuel, be very careful when handling the tank as it will be heavy and harder to balance.
• Clean the area around the fuel pump to prevent dirt and debris from falling into the fuel tank when you remove the pump.
• Have a fire extinguisher nearby in case of fire.
• If you are jacking up the vehicle, ensure it is safely raised and supported, and use jack stands. Set the parking brake and chock the front wheels.
• Consult your vehicle's service manual or online tutorials for specific guidance on safety precautions and the procedure for your particular vehicle.

Locating the fuel pump

All vehicles with fuel injection have a primary fuel pump that is typically located in the fuel tank. Modern vehicles with gasoline direct injection (GDI) also have a second pump, which is a high-pressure pump. This second fuel pump is located near the fuel rail in the engine compartment.

Some vehicles have a fuel pump access door underneath the rear seat, allowing you to access the pump from inside the cabin. In other cases, you may need to drop the fuel tank to access the pump.

If you are upgrading a classic car to fuel injection, you may need to install the fuel pump in the engine bay, under the car attached to the frame, or in the trunk near the fuel tank. It is important to note that fuel pumps are "pushers" rather than "suckers", so they need to be located where they can have a constant presence of fuel. This means that the best location for the pump is in the tank or as close to the tank as possible, preferably lower than the tank to take advantage of gravity.

Removing the fuel tank

Prepare the Workspace and Gather Equipment:

• Ensure you have a safe and accessible workspace, preferably outdoors or in a well-ventilated area, to minimise the risk of fire and inhaling toxic fumes.
• Gather the necessary tools and safety equipment, including safety glasses, gloves, and approved containers for storing fuel.
• Have cleanup materials ready to immediately clean any spills.
• Keep a fire extinguisher nearby as a precaution.

Relieve Fuel System Pressure:

• Before accessing the fuel tank, it is crucial to relieve the fuel system pressure.
• You can do this by running the engine and pulling the fuel pump relay, which will cause the engine to stall. Alternatively, with the engine off, locate the Schrader valve on the pressure line and press it momentarily to release the fuel spray.

Remove Fuel from the Tank:

Siphon the fuel out of the tank and store it in approved containers. This step is important to reduce the risk of spills and make the tank lighter and easier to handle.

Disconnect Hoses and Electrical Connectors:

• Disconnect all the hoses, including supply lines, return lines, and vent hoses.
• Once the fuel lines are disconnected, proceed to disconnect the electrical connectors.

Loosen Metal Straps and Support the Tank:

• Loosen the nuts or bolts on the metal straps holding the tank in place.
• Be ready to support the tank as you remove the straps to prevent it from falling.

Lower and Remove the Fuel Tank:

• Use a jack to support and lower the fuel tank carefully.
• Depending on your vehicle, you may need to access the tank from underneath, through an access port under the rear seat or in the trunk area.

Remember to work carefully and follow the specific instructions for your vehicle. Always put safety first when dealing with flammable liquids.

Disconnecting the fuel lines

Push-Type Connector:

• Identify the type of push-type connector you have. Some have a push point on both sides, while others have a push point on only one side.
• For the two-sided version, push from both directions to release the connector.
• For the one-sided version, simply push it down and pull it off.
• To reinstall, push the connector onto the fitting until you hear a clicking sound.

Push-and-Lock Style Connector:

• Push the connector onto the fitting.
• Push the locking tab through. There is a safety line beneath the fitting.
• To remove, release the safety latch and push the connector back through.

Pinch-Type Connector:

• Locate the retainers on each side of the connector.
• Pinch the retainers together to disconnect the connector.
• To reinstall, you have two options: leave the retainer on the male end and slide the female fitting over it, or remove the retainer and slide the fitting onto the male end until it clicks.

Spring-Style Retainer Fitting:

• To install, slide the fitting onto the connector until you hear a click.
• To remove, locate the black ring on the fitting and pull it back toward the connector. Then, pull the fitting off.

Hose and Clamp Style Fitting:

• This type is typically used for emissions lines.
• Use pliers to pinch the clamp together and slide it back.
• Pull the line off the fitting.

Horseshoe-Type Fitting:

• Use a screwdriver to pry the horseshoe-shaped clip out and up, releasing it from the fitting.
• To install, insert a new horseshoe clip into the fitting, then slide it onto the fuel line until you hear a click.

It is important to note that fuel lines can sometimes break during the removal process, leaving part of the line stuck in the fitting. In such cases, use a release tool and insert a screw or bolt that fits into the line to remove the fitting.

Reassembling the fuel system

Once you have removed the old fuel pump, cleaned the area, and installed the new pump, you can begin reassembling the fuel system.

First, reconnect the fuel lines to the pump, ensuring they are securely attached. Then, lift the fuel tank back into place and install the retaining strap. Reattach the filler tube hose and the electrical connector.

Next, reconnect the negative battery cable and fill the tank with gas. It is important to conduct a road test to confirm that the repair was successful and the new fuel pump is functioning properly.

Finally, consult your vehicle's service manual or online tutorials for specific guidance on reassembling the fuel system, as the process may vary depending on your vehicle's make and model.

• Ensure that the area around the fuel pump is clean and free of debris before reconnecting the fuel lines.
• Verify that the new fuel pump is the correct part for your vehicle by comparing it to the original pump.
• Be careful not to overtighten any connections or hoses, as this can cause damage.
• Check for leaks after reassembling the fuel system and before starting the vehicle.

Frequently asked questions