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how to replace a fuel pump

Use this step-by-step guide to replace an electric fuel pump. Work in an open, well-ventilated area and keep a fire extinguisher nearby in case of an emergency.

Have on hand:

• Replacement fuel pump
• New fuel line
• Open-end wrench set
• Socket set
• Flathead screwdriver
• Phillips-head screwdriver
• Large container to catch fuel

1. Cut fuel pump power/relieve fuel pressure
The high fuel pressure produced by an electric fuel pump doesn't go away just because you turn off your engine. You must release the fuel pressure before you removing the fuel pump and its parts. One you’re sure there’s no pressure in the fuel lines or pump, you can replace the pump.

• IMPORTANT: Disconnect the negative terminal to your battery before you proceed to avoid sparks.
• Locate the fuel pump fuse in your fuse box, or, if you don’t have a specific fuel pump fuse, find the relay to the pump.
• Start the car, and with the engine running, pull out the fuel pump fuse or relay.
• The engine will quit and now your fuel lines will lose pressure.

2. Unbolt the fuel pump – but don’t remove it yet!
Electric fuel pumps are mounted either under the car, just in front of the fuel tank, or inside the fuel tank.

• Under-car mounted pumps are bolted in place, often inside a black insulating sleeve. Slide under a securely jacked car and look just in front of the gas tank. If you can’t locate it easily, follow the fuel line from the tank to the fuel pump. Unbolt the pump and allow it to drop down.
• In-tank pumps can be removed from an access point inside the car, usually either under the back seat or under an access panel in the trunk. 

3. Now disconnect the fuel lines
Under-car pumps have two lines – one in and one out, also called low pressure and high pressure lines. In-tank pumps have a single line off the top of the pump.

• IMPORTANT: Be ready with a container to catch any fuel that leaks from the lines as you disconnect them.

• Loosen the hose clamp or fittings holding the lines, then remove the lines.

4. Disconnect the wiring and remove the pump
There are two wires powering the pump, a positive wire and a ground wire. Note or label the wires to ensure you rewire your new pump correctly.

• Remove the wires by loosening the plugs, screws or bolts holding them in place.
• Safely remove the entire pump and recycle it if possible

5. Install your new fuel pump
Reverse the steps you just took, hooking up the wiring, then the fuel lines, bolting in your new pump and reinserting the fuel pump fuse or relay. Reconnect your battery, crank the engine, check for leaks and then get back on the road!

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