How to Install an Aftermarket Electric In-Tank Fuel Pump
The electronic fuel pump in a gas tank not only provides fuel to the engine. It also pressurizes the fuel system for fuel injection, screens the gasoline to keep contaminants from the fuel system, and provides electronic feedback to the cars engine-control unit (ECU) on the pump's status. In the event of pump failure, the engine may receive fuel erratically, experience low pressure, or in some cases fail to provide sufficient fuel for combustion.
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Things You'll Need
- Socket set
- Socket wrench
- Socket extension
- Large vehicle jack
- Jack stands
- Chocks
- Siphon and tubing
- Fuel pump
- Fuel pump gasket
- Fuel-resistant RTV silicone gasket maker
- Empty gas cans
- One-inch-thick, one-foot-square wood board
- Spray break cleaner
- Clean cloth
- Pliers
- Screwdriver
- Fuel line removal tool
Instructions
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1
Depressurize the fuel system. Remove the fuel inertia cut-off switch plug (see owners' manual for exact location). Start the vehicle several times to reduce the fuel pressure in the lines. Remove the negative cable from the battery terminal.
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2
Stabilize the vehicle with wheel chocks. If necessary for access to the fuel tank, lift the vehicle on jacks and stabilize with jack stands.
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3
Remove the fuel from the fuel tank. Use the flexible tubing with the siphon pump: insert one end of the tube into the fuel tank and the other end into an empty gas can. Place the gas can lower than the gas tank. Siphon the fuel into the gas can. Use multiple cans if necessary. If your vehicle is equipped with a safety screen (which will not allow gas siphoning), it will be necessary to siphon the gas when the gas tank filler tube is disconnected.
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4
Place the board under the gas center of the gas tank. Use the large vehicle jack to brace the gas tank. Loosen each of the retaining bolts on the gas tank (usually on the straps holding it in place). Lower the fuel tank partially with the jack to allow access to the fuel lines, the gas filler tube (which leads to the gas filler cap), and the electronics. Disconnect all attached lines and clips. Siphon gas from tank if not completed in Step 3. Remove bolts and lower the gas tank as necessary to reach components.
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5
Remove the gas tank from under the vehicle. Locate the fuel pump on the gas tank and find the retaining bracket holding the fuel pump in place. Clean the area around the fuel pump to reduce the risk of contaminating the inside of the gas tank during removal and installation of the pump. Remove the retaining bracket (typically a circular threaded bracket requiring turning to remove). Remove the fuel pump and the fuel pump gasket
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6
Remove all old gasket material and clean the gasket area thoroughly with the brake cleaner and a clean cloth. Place a thin layer of new RTV silicone gasket material in the gasket groove and place the new gasket in the groove. Place another layer of RTV silicone gasket maker on top of the gasket. Install the new fuel pump with the connections facing the same direction as the old pump. Attach any retaining devices to thoroughly secure the pump in place.
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7
Replace the gas tank using the wood and jack as a lift to help stabilize the tank during installation. Replace the fuel-filler line, the fuel lines, and any electronics on the fuel pump. Replace the gas tank straps and bolts.
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8
Replace the negative battery cable to the terminal and the fuel inertia safety switch plug. Turn the vehicle on (but do not start) and wait five seconds to allow the fuel lines to pressurize. Repeat the pressurization. Look for and address leaks, if necessary. Turn on vehicle.
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1
Tips & Warnings
Due to the awkward size and location of the gas tank, having multiple individuals available to assist in its removal and replacement will make the job easier.
The locking nut is usually about the same size as the opening in which the fuel pump is inserted and made of the same material as the gas tank.
A fuel-line removal tool may be required to remove some fuel lines, depending on your car's manufacturer. The parts are available in automotive parts stores and are usually vehicle-manufacturer specific.
Have a fire extinguisher available when working around fuel and electronics.
To dislodge a tight locking nut, use a rubber mallet and a cloth covered screw driver and tap the outer edge of the locking nut to dislodge. Do not use a metal hammer or strike the metal of the screwdriver against other metal parts. Sparks may result in fire or explosion of gasoline fumes.
References
- Photo Credit Tankstelle image by Ewe Degiampietro from Fotolia.com
