Replacing an in Tank Fuel Pump
There are two main types of electric fuel pumps. An inline fuel pump which just attatches to your fuel line and runs wires to the battery, or an in-tank fuel pump.
In most cases, you are only going to see the inline fuel pump as an aftermarket part. It is usually added on to older vehicles and is pretty straight forward when it comes to changing them.
Changing an in-tank fuel pump is not as difficult as you would think, it is just an awkward job to do, expecially if you have an extremely large fuel tank. Let go over some basic steps to removing most fuel tanks to access your fuel pump, and then removing the fuel pump itself.
- Caution* It is wise to make sure your tank is mostly empty before you let it down from its straps.
1) Most fuel tanks are held on buy to very large metal straps that secure the tank to the car. You will need some really good penetrating oil and a breaker bar to get them lose.
2) Remove the bolts from the straps, and try to remove the ones nearest to the back of the vehicle first if you can. Have a jack ready before you do this and/or a second person to help you. Most fuel tanks are extremely heavy and you will want to let it down gently to avoid injury to you or to the tank.
3) Once you have undone the one side of both straps, let the tank down slowly, but do not let it touch the ground. In most cases, your electric fuel pump will have fuel lines and electrical line running to it through the top of the tank, and you will want to be careful not to pinch any lines or break any wires.
4) You want to try and remove the fuel pump from the tank this way. One way I have found that helps a little it to jack the back up of the vehicle up to give the tank a little more room so that you can access the O ring you need to get to. Just be careful because it you let the tank lean to much you will not be able to break the seal around the O ring.
5) The O ring itself is just a piece of metal shaped like an O that fits around the top of the fuel pump and seals it to the tank by 'locking' it into place. In order to remove it you will need a flat tip screw driver and a good hammer that will fit into the space you have to work with. Put the screw drivers tip onto one of the 'lips' around the O ring and use the hammer to 'unlock' the O ring. This may take a few times, just remember "Righty Tighty, Lefty Loosey"
6) Once you have the O ring loosened, you should be able to pull it up and around the fuel lines and get it out of the way of pulling the pump out. This may be easier said than done though and you might have to lower the rear of the car or jack it up more to get the fuel pump to come out nicely. You will want to be careful not to break anything as the part will fall in the tank and you'll never get it back out.
7) Pull out the electric fuel pump. There should be one or two small harnesses attatched to it. Make sure to remember where they came off. Remove the fuel lines that are attatched to it and anything else holding it to the vehicle. Once you have done that you can put the new one in place and attatch everything that came off of the old one.
8) put the newly attatched fuel pump in the top of the tank and place the O ring back into its position. You will want to 'lock' it into place by turning it in the opposite direction you turned it to get it off. Use your screw driver and hammer to get it there.
9) Once you are sure that the O ring is secure and you have a tight seal, use your jack to lift the tank back into place and re-attach its straps.
10) Fill your tank up with gas and see how she runs!
Wal La! You have just replaced your electric fuel pump!
