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How to remove and replace your fuel pump

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Fuel Management Fuel Systems How to Technicians 2 min read

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In this article you will find out about how to remove and replace your fuel pump safely.

Replacing a fuel pump won’t look the same for every vehicle, but these basic steps are a good place to start.

First, make sure your vehicle doesn’t have an access panel that will allow you to access the pump without removing the tank. We’ll show you what to do if you do need to drop the tank.

Safety first

We always put safety first, so make sure you’re thorough and careful. Don’t forget to wear safety glasses and gloves. Give yourself room to work and have cleanup materials ready to clean any spills immediately. Work in a well-ventilated area away from an open flame or anything that could cause a spark or ignite fuel, such as pilot lights and incandescent light bulbs. Make sure you have a fire extinguisher on hand. Don’t smoke, either. Always relieve fuel pressure prior to opening fuel systems because releasing fuel under pressure can cause fire and injury. Store fuel in an approved container like a gas caddy or gas can. 

Be sure to use a support jack.

Procedure for replacing your fuel pump

First, you’ll need to lift the vehicle so you can remove the tank. If there’s gas in the tank, you’ll have to drain it into an approved container first.

It's important to clean the tank thoroughly during the repair.

Next, remove the clamps from the fill lines and then remove the fill lines as you prepare to drop the gas tank. You can use a rag to avoid getting dirt in the tank. Make sure to support the tank as you remove the straps and carefully lower the gas tank.

Remove the pump assembly so you can replace it with a brand-new part. Keep in mind that some fuel pumps require parts to be transferred from the old unit.

And then you just need to reverse the procedure. Get the pump installed and the pump retaining ring back in place and raise the tank close to the vehicle so you can reconnect the wire connectors and fuel lines. Reconnect the straps and fill lines with the tank properly positioned. Partially fill the tank and run the vehicle so that you can inspect for any leaks.

And you’ve done it. Just be careful and follow safety precautions and you can be back on the road in no time. Don’t forget to replace the fuel filter as well so that your new pump will run smoothly.

See detailed videos on how to replace a fuel pump in our how-to series on YouTube.

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