Wednesday, 15 April 2015

How to Replace a Fuel Pump Assembly

Fuel Pump Assembly Replacement

Safety Tip:
Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.

Park the vehicle on a solid, level surface and set the parking brake.
Open the fuel door and remove the filler cap. Have an assistant turn the key to the ON position while you listen for a hum coming from the filler opening. If there is no sound, the fuel pump may need to be replaced.
Check the fuel pump fuse and relay. Refer to your vehicle owner's manual for the exact locations.
If the fuse and relay are good, check for power and ground at the fuel pump. Removing the rear seat or the fuel tank may be necessary. If the fuel tank needs to be removed, siphon or drain as much fuel as possible from the tank. Use proper safety precautions and store the fuel in an approved container.
For vehicles with an access cover, remove the rear seat to expose the cover. Remove the cover.
For vehicles without an access cover, support the fuel tank with a jack and a block of wood. Remove the mounting straps and the filler tube hose. Carefully lower the fuel tank.
Turn the key to the ON position and check for power at the fuel pump assembly. Touch the negative lead from the digital multi-meter (DMM) to a good ground and the positive lead of the DMM to the power cable at the fuel pump assembly. If the voltage is good, you will need to replace the fuel pump assembly. If you do not have a reading, you will need to inspect the power side of the fuel pump assembly.
Relieve the fuel pressure and disconnect the negative battery cable. Remove any electrical connections and fuel lines from the fuel pump assembly.
Remove any retaining bolts that hold the fuel pump in the fuel tank.
Remove the fuel pump assembly by pulling it out of the tank.
Compare the new fuel pump assembly to the old one to make sure it is the correct fit and match.
Install the new seal or gasket (if equipped). Install the new fuel pump assembly inside the tank. Tighten the retaining bolts.
Connect the fuel lines and the electrical wires.
Re-install the fuel tank or the access cover and rear seat.
Reconnect the negative battery cable and add fuel if necessary. Start the engine and check for leaks.

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