ALT-1 How to Replace an Electric Fuel Pump
How to Replace The Fuel Pump on Your Car
In todays electronic age, just about all fuel pumps in the newer vehicles, are electrical, and just about all of them are located inside the fuel tank. So in reality, there is only one way to replace the fuel pump in most newer vehicles.
The most difficult part of this procedure after disconnecting the electrical connections and fuel lines on the top of the gas tank, is removing the fuel tank itself! The very first thing that has to be one is to remove all the fuel from the tank itself. This requiring a little siphon bulb, with hose that you can purchase from just about any auto parts store. These can also be obtained from Walmart on most occasions, for substantially less. Around seven dollars or so.
In most normal vehicles, there are two heavy metal straps that hold the fuel tank in place. The very first thing you do is to drive the vehicle up on to a set of car ramps. Giving you room to work under the vehicle. Next, remove all fuel from the tank.
Once you have removed the fuel from the tank. You use a standard hydralic floor jack, centered under the middle of the fuel tank. Close off the air valve on the base of the jack, and begin to pump up the pressure until the hydralic foot of the jack comes into contact with the bottom center of the fuel tank. At this point, continue to pump the jack until the weight of the tank comes up off the retaining straps.
At this stage, it's either a 9/16 or a 25 millimeter size socket. Using the same size wrench for the nut on top and the socket and socket wrench on the bottom of the bolt, remove the bolt nut, and washer from all four retaing bolt's which hold the straps in place. Once this is done. The retaining straps can be removed from underneath the bottom of the fuel tank, and taken out off the way. entirely! This will leave the fuel tank just sitting on top of the hydralic arm of the jack.
At this stage, make sure that you have removed the wiring plug, which attaches to the fuel pump, the fuel line, and the ground wire which attaches to the frame, from the tank. Once this is done, slowly release the pressure at the pressure screw on the base of the jack. This will slowly lower the fuel tank to the ground. Once this is completed, the fuel tank should be totally free, and can be removed from underneath the vehicle.
At this stage, looking at the top of the fuel tank. You will see where the fuel line. The electrical plug-in for the fuel pump and the ground wire attach to the tank. They will all be centered inside a large, circular retaing ring, on top of the tank. This circular ring is removed by using a horseshoe type wrench, that clips into each side of the retaining ring.Once the tool is in place, gently, keeping even pressure on both sides of the tool, turn towards yourself, or to the left, to remove the entire assembly. Once broken free, loosen the rest of the way with your hands. When it's loose, the whole thing lifts straight up and out and you see the actual fuel pump for the first time.
There will be two or four small bolts that hold the fuel pump to the round, circular mount. Remove these small bolts, and the entire fuel pump and wiring harness will come off free, into your hands, and at this time, the old fuel pump is removed!
All thats left is to simply reverse the procedure to put the new pump into place. Believe me. Once you're at this stage, the hard parts are done and it's all down-hill from here. Simply replace the old pump with the new. Re-attach the fuel line, and wiring harness, it's just one plug in and the ground wire, and this stage is complete.
Put the fuel tank back into the proper place. Lift into place with the hydralic jack. Reinstall the retaining straps, making sure that everything is tightened properly, and that the fill neck is seated properly. Tighten the screws that hold the fill neck to the body. Thats where the gas cap goes, and for all intents and purposes, your done!
Lower the jack from the bottom of the tank. Replace the gas back into the gas tank. Let it sit for a few minutes. Turn the motor over a few times to prime the pump, and start it up! Remove the hydralic jack. Back the vehicle off the car ramps, and that my friends, is called a Done Deal! You are offically back on the road!
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