How to Replace Electric In-Tank Fuel Pumps

The first thing to consider when replacing an electric fuel pump is how much fuel is in the tank. If the tank is over half full, fuel must be drained out so that it will not spill when the hoses are disconnected and the tank is tipped. It is dangerous opening up a fuel tank if the proper precautions are not taken, such as making sure no one is smoking and there are no flames nearby.

Things You'll Need

• Set of 3/8-inch sockets
• Hammer
• Screwdriver
• Ratchet

Instructions

1. Jack the vehicle high enough to slide the tank out from under the vehicle. Support it with jack stands. Disconnect the fuel pump wiring harness connector at the fuel tank. Loosen the hose clamps on the filler hose where it attaches to the fuel tank. Loosen the hose clamps on the overflow hose, which is next to the filler hose. Remove the filler and overflow hoses from the fuel tank using a common screwdriver to pry them off.

2. Place the jack under the fuel tank and make sure it is centered. Remove the two bolts in the straps holding the tank up. Once the bolts are removed, pull the straps down and push them out of the way.

3. Begin to lower the tank until there is enough clearance on top of the tank to remove the fuel lines attached to the pump. The pump will be centered in the tank. The fuel lines can be removed by loosening the clamps with a common screwdriver and pulling them off. The third line--the vapor line connector--is made of plastic and is designed to come off by squeezing it with your fingers, which spreads it apart and allows it to be pulled off.

4. Lower the tank to the floor and slide it out from under the vehicle. The fuel pump is held in by one of two ways: it either has a round screw-on cap, which is easily unscrewed, or it has a flat ring with tangs on it. The ring has corresponding tangs on the tank. Place the screwdriver on the inside tang and tap it with the hammer (counterclockwise) to release it.

5. Lift the fuel pump from the tank. Note the direction it is pointing at the top where the fuel connectors are. Also note the position of the fuel sending unit float as it is extracted so the new pump can be installed the same way. Install the new pump the same way it came out. Install the new o-ring that came with it on the top of the tank under the cap. If you have a screw-on type, screw the cap on. If you have the ring, lay it flat and start it in the tangs by hand, then tap it clockwise with the screwdriver and hammer.

6. Lift the tank up enough (using the jack) to install the fuel lines. Plug in the fuel pump wiring connector. Lift the tank into its proper position all the way up and position the straps around the tank. Insert the bolts in the strap and tighten them.

7. Remove the jack and push the fuel filler line on, as well as the overflow line, and tighten the clamps. Remove the jack stands and let the vehicle down.