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Replacing the Fuel Pump

How to replace the fuel pump on your car

Fuel pumps fail for many reasons, and it is advisable to determine the reason before replacing the fuel pump. Should the cause of the failure be contamination or debris in the fuel system, then this should be removed before the new fuel pump is installed. Always test the old fuel pump to ensure that the fault lies with the fuel pump, and not with any other component of the engine’s fuel system.

REPLACING A MANUAL FUEL PUMP

STEP 1:
Remove the inlet and outlet hoses from the old fuel pump, and plug them to prevent fuel loss.

STEP 2:
Loosen the two retaining bolts / nuts that secure the fuel pump to the head/block. Check which side the rocker arm operates either below or above the camshaft lobe. Remove the fuel pump.

STEP 3:
Fit the new fuel pump, ensuring that the fuel pump rocker arm is installed with the camshaft lobe in the correct position. This will ensure that the minimum force is applied to the rocker arm, and that the fuel pump diaphragm is not damaged during installation. Check all of the relevant connections and fittings for possible leaks.

REPLACING AN ELECTRIC FUEL PUMP

STEP 1:
Locate the position of the fuel pump. The fuel pump could be located inside the fuel tank itself, outside the fuel tank, or in the engine compartment. Remove the fuel pump and fuel lines. Inspect and clean the surrounding area to ensure that any contaminants and / or foreign materials are removed.

STEP 2:
Open the engine end of the fuel pipe, and blow the fuel lines clear of any foreign material. Install the new fuel pump and fuel filter, and reconnect the fuel lines securely.

STEP 3:
Fill the fuel tank with uncontaminated fuel. Should you so wish, you can use a fuel pressure tester to ensure that the fuel pressure and flow volume are within the required specifications.

STEP 4:
Remove any test equipment used and double check all of the relevant connections and fittings for any possible leaks.

USEFUL TIP 1:
Check your fuel hoses and pipes for defects and wear approximately once every three months.

USEFUL TIP 2:
It is recommended that one should never drive a vehicle with less that 20% of the fuel capacity in the fuel tank. This will minimise the risk of contaminants and water residue damaging the fuel system.

Download a PDF on Replacing the Fuel Pump