How to Change an In-Tank Electric Fuel Pump

Cars with fuel injection use an electric fuel pump that is located inside the gas tank. This is a safe spot, away from moisture, road hazards and debris. Since there is little air inside the closed fuel system, this helps to prevent a fire of explosion in case of a malfunction. If an electric fuel pump fails, you will have to remove the gas tank to replace it.

Difficulty: Moderate

Instructions

Things You'll Need:

• Jack
• Safety stands
• Wrench
• Socket wrench
• Pliers
• Screwdriver

1. Jack up the car and support it with safety stands. Be sure the car is high enough to get the tank out from underneath the car. You could use a car lift instead. If you use a lift, you will need an automatic transmission jack or a second person to help you lower the tank to the ground.

2. Unclamp and remove the filler and vent hoses from the gas tank. Most are held on with aero type hose clamps. Unplug any wiring to the fuel pump and sensors. Using wrenches or pliers, remove the fuel lines at the pump. You might need to lower the tank one to two feet to remove the lines and wires.

3. Support the gas tank with the jack. Use socket wrenches to unbolt the gas tank straps. Remove or reposition the straps out of the way of the tank. Lower the tank some and check to make sure all lines, hoses and wires have been removed. Continue lowering the tank and place it on the ground.

4. Clean the tank area around the fuel pump assembly of all dirt and debris. Release the pump assembly retainer. This may held to the tank with a clamp, a slip ring or screw nuts. Remove the pump assembly from the tank. Drain any liquid fuel from the assembly and place on a work bench.

5. Remove the pump from the assembly and discard or replace the entire assembly. Some pumps can only be replaced as a unit. If you can replace just the pump be sure to install the new sock filter that comes with the pump.

6. Return the repaired pump assembly to the tank. Use new gaskets or O-rings if supplied. Secure it into the tank with the retainer.

7. Place the gas tank back onto the jack and raise it to the car. Reinstall the fuel lines, hoses and wiring. Continue raising into its cavity on the body. Secure the tank with the gas tank straps and tighten with a socket wrench.

8. Reinstall the filler and vent hoses. Tighten the clamps. It is a good idea to also replace the fuel filter at this time. Lower the car to the ground. Test for leaks and repair any found.

Tips & Warnings

• Cover any holes in the tank to reduce the amount of fumes escaping from the tank.
• Pour fuel from tank into approved container.
• Always use safety stands when getting under a raised car.

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