Fuel Pump Replacement: Where To Go For A New One?

Replacing a fuel pump can be a challenging task, but with the right tools and precautions, it can be done safely and efficiently. Fuel pumps are responsible for transferring fuel from the tank to the engine, where it is aerosolized by fuel injectors and combusted to produce power. While they are durable, fuel pumps can fail due to various reasons, and it is essential to address any issues promptly to avoid bigger and more expensive problems. The cost of replacing a fuel pump can vary significantly, depending on the vehicle's make and model, with prices ranging from under $100 to over $2000. It is recommended to consult a professional mechanic or refer to the factory repair manual for specific instructions and safety precautions before attempting any repairs.

In-tank fuel pump replacement

Overview

Fuel pumps are generally located inside the fuel tank. To replace an in-tank fuel pump, you will need to remove the fuel tank from the vehicle. This process can be complex and time-consuming, and it is important to take the necessary safety precautions when working with flammable liquids.

Steps for In-Tank Fuel Pump Replacement

• Safety first: Put on safety glasses and keep a fire extinguisher nearby.
• Prepare the vehicle: Park the vehicle on a firm, level surface and engage the parking brake. Disconnect the negative battery cable.
• Relieve fuel system pressure: Follow the procedure in your vehicle's repair manual.
• Drain the fuel tank: Use a hand pump or siphon to drain the fuel tank if it contains a significant amount of fuel. This step is optional but will make the tank lighter and easier to handle.
• Disconnect the fuel filler neck: Loosen the clamp on the fuel filler neck and disconnect it from the fuel tank.
• Support and lower the fuel tank: Use a jack to support the fuel tank and remove the fuel tank strap bolts and straps. Lower the tank enough to access and disconnect the fuel hoses, electrical connections, and emissions hoses.
• Remove the old fuel pump: Clean the area around the pump access hole to prevent dirt and debris from entering the tank. Remove the retainer ring or bolts securing the pump assembly to the tank. Take out the old fuel pump and seal ring.
• Install the new fuel pump: Compare the new pump to the old one to ensure they match. Install the new seal ring and pump assembly in the tank.
• Reconnect the fuel tank: Use the jack to raise the tank and reconnect the fuel hoses, electrical connections, and emissions hoses. Reinstall the fuel filler neck and secure it with a clamp. Reinstall the fuel tank straps and torque the mounting bolts to the specified tension.
• Lower the vehicle and reconnect the battery: Safely remove the jack stands and lower the vehicle. Reconnect the negative battery cable.
• Refill the fuel tank and test: Refill the fuel tank as needed and start the vehicle to test the new fuel pump, checking for leaks.

Tips for In-Tank Fuel Pump Replacement

• Work in a well-ventilated area, preferably outdoors, to minimise the risk of fire and inhalation of fumes.
• Always wear safety gear, including safety glasses, gloves, and appropriate clothing, to protect against fuel spills and splashes.
• Consult your vehicle's service manual or online tutorials for specific guidance on fuel pump replacement for your vehicle.
• Consider replacing related components such as the fuel filter, fuel pump strainer, and fuel tank O-ring or gasket.

Pump with an under-seat access cover

If you're looking to replace your fuel pump, the first step is to locate it. In most vehicles, the fuel pump is located within the fuel tank, which can be found at the rear of the vehicle.

However, some vehicles have an access port under the rear seat, which makes it much easier to reach the fuel pump without having to lower the entire tank. This is often the case with Volkswagen vehicles, for example. To access the fuel pump in this case, simply remove the rear seat and move the carpet.

If your vehicle does not have an under-seat access port, you will need to lower the fuel tank to access the fuel pump. Here are the steps to do so:

• Park your vehicle on a firm, level surface and engage the parking brake.
• Open the fuel cap and turn the key to the "on" position. Listen at the filler opening. If the fuel pump is working properly, you should hear a hum for two to three seconds. If you don't hear anything, it may be necessary to replace the pump.
• Find and verify the fuel pump fuse and relay. If the fuse is blown, replace it with one of the same amperage and check the fuel pump operation.
• If the fuse and relay are functional, check for power and ground at the fuel pump. If there is power and ground, then the pump is faulty and needs to be replaced.
• Relieve the fuel system pressure by disconnecting the negative battery cable.
• Siphon or drain as much fuel as possible from the fuel tank to reduce the risk of spills.
• Disconnect the filler tube hose and any electrical connections to the pump.
• Use a jack and a block of wood to support the fuel tank. Remove any retaining straps or bolts holding the tank to the frame, and carefully lower it.
• Disconnect the fuel lines and remove the old fuel pump from the tank.
• Compare the new fuel pump with the original to ensure you have the correct part.
• Install the new fuel pump, reconnect the fuel lines, and secure the tank back into place.
• Reconnect the filler tube hose and the electrical connector, and reconnect the negative battery cable.
• Refill the tank with fuel and conduct a road test to confirm that the repair was successful.

Remember to always consult your vehicle's service manual or online tutorials for specific guidance on replacing the fuel pump in your particular vehicle. Working with fuel can be dangerous, so it is important to take proper safety precautions and work in a well-ventilated area.

Locating the fuel pump

Some vehicles have a fuel pump access door underneath the rear seat, allowing you to access the pump from inside the cabin without removing the fuel tank. If your vehicle does not have such an access door, you will need to remove the fuel tank to access the pump. This typically involves unbolting the straps that hold the tank in place and using a jack to lower it.

It is important to note that modern vehicles with gasoline direct injection (GDI) have a second, high-pressure pump located near the fuel rail in the engine compartment. This pump should be easier to access and does not require removing the fuel tank.

Additionally, when locating the fuel pump, it is crucial to prioritize safety. Make sure the vehicle is turned off and securely parked on a level surface before attempting to access the pump.

Replacing the fuel pump

When to Replace a Fuel Pump

If you notice any issues with your engine's performance, it is advisable to have it checked out as soon as possible. Some signs of a faulty fuel pump include:

• Difficulty starting the car
• Loss of power while driving
• Engine stalling
• Strange, high-pitched noises coming from the fuel tank area

Preparations for Replacing a Fuel Pump

Before starting, ensure you have gathered all the necessary tools and equipment, including a new fuel pump, fuel filter, and any other components specific to your vehicle. It is also recommended to reduce the amount of fuel in the tank to minimise the risk of spillage and make the tank lighter and easier to handle.

Step-by-Step Guide to Replacing a Fuel Pump

The following steps outline a typical in-tank fuel pump replacement:

• Park your vehicle on a firm, level surface and engage the parking brake.
• Locate the fuel pump, which is usually inside the fuel tank. Open the fuel cap and turn the key to the "ON" position. If you hear a brief hum, the pump is functioning correctly. If not, it may need to be replaced.
• Find and verify the fuel pump fuse and relay. If the fuse is blown, replace it with one of the same amperage and check the pump's operation.
• If the fuse and relay are functional, check for power and ground at the fuel pump. If there is power and ground, the pump is faulty and needs replacement.
• Relieve the fuel system pressure by running the engine and pulling the fuel pump relay, or by pressing the Schrader valve on the pressure line momentarily to release the fuel spray.
• Siphon or drain as much fuel as possible from the fuel tank to reduce the risk of spills.
• Disconnect the filler tube hose and the electrical connection to the pump.
• Support the fuel tank with a jack and a block of wood. Remove any retaining straps or bolts holding the tank in place.
• Lower the fuel tank.
• Disconnect the fuel lines and remove the old fuel pump from the tank.
• Compare the new fuel pump with the original to ensure you have the correct part.
• Install the new fuel pump and connect the fuel lines to it.
• Lift the fuel tank and reinstall the retaining strap. Reconnect the filler tube hose and electrical connector.
• Reconnect the negative battery cable, fill the tank with fuel, and conduct a road test to confirm the repair.

Tips for Replacing a Fuel Pump

• Work in a well-ventilated area to minimise the risk of fire and inhalation of harmful fumes.
• Wear safety gear, including glasses, gloves, and appropriate clothing, to protect yourself from fuel spills.
• Clean around the fuel pump to prevent dirt and debris from falling into the fuel tank.
• Consider replacing related components such as the fuel filter, fuel pump strainer, and fuel tank gasket.
• Consult your vehicle's service manual or online tutorials for specific guidance on replacing the fuel pump in your car model.

Safety precautions

Before attempting to replace a fuel pump, it is important to take several safety precautions to ensure the process is carried out safely and effectively. Here is a step-by-step guide on how to do this:

Step 1: Prepare the Vehicle and Workspace

Park your vehicle on a firm, level surface and engage the parking brake. It is also recommended to have a safe and accessible workspace, preferably outdoors, to minimise the risk of fire or inhalation of harmful fumes. Ensure you have all the necessary tools and equipment, including safety gear such as safety glasses, gloves, and appropriate clothing to protect yourself from fuel spills and splashes.

Step 2: Check the Fuel Pump

Before proceeding with any replacement, it is important to confirm that the fuel pump is faulty. Check for common symptoms of a faulty fuel pump, such as difficulty starting the car, sudden loss of power while driving, rough running or stalling, and strange, high-pitched whining noises coming from the fuel tank area. If you notice any of these issues, it is best to consult a professional mechanic for further diagnosis and repair.

Step 3: Reduce Fuel Level

As most fuel pumps are located directly in the fuel tank, it is recommended to reduce the amount of fuel in the tank to prevent spillage and make the tank lighter and easier to handle. Use a hand-operated pump or siphon to drain the fuel. Alternatively, you can drive your vehicle until the fuel level is low.

Step 4: Disconnect the Battery and Relieve Fuel System Pressure

Disconnect the negative battery cable to cut off power to the fuel pump. Then, relieve the fuel system pressure by running the engine and pulling the fuel pump relay, which will cause the engine to stall. Alternatively, with the engine off, you can press the Schrader valve on the pressure line momentarily to release the fuel pressure.

Step 5: Locate and Remove the Fuel Tank

Locate the fuel tank and remove it from the vehicle, if necessary. This process may vary depending on the vehicle model. In some cases, you may need to use a jack to support and lower the fuel tank. Always refer to the vehicle's service manual or online tutorials for specific instructions.

Step 6: Disconnect Fuel Lines and Electrical Connections

Before removing the old fuel pump, take note of the fuel line connections and wiring. Disconnect all fuel lines and electrical connections to the fuel pump. This may include removing the filler tube hose and any retaining straps or bolts holding the tank in place.

Step 7: Remove and Replace the Fuel Pump

Once all connections have been disconnected, remove the old fuel pump by turning the large lock nut and pulling it out. Compare the new fuel pump with the old one to ensure you have the correct part. Then, install the new fuel pump, reassemble the fuel system, and reconnect all the fuel lines and electrical connections.

Step 8: Reinstall the Fuel Tank and Refuel

After installing the new fuel pump, raise the fuel tank back into place and reinstall any retaining straps or bolts. Reconnect the negative battery cable and fill the fuel tank as needed. Finally, start the vehicle and test the new fuel pump to ensure it is functioning properly.

By following these safety precautions and referring to vehicle-specific instructions, you can replace a fuel pump effectively while minimising risks associated with handling flammable liquids.

Frequently asked questions