Fuel Injection In-Tank Fuel Pump Replacement Instructions
Fuel pump installation tends to be a difficult task. It is definitely one you do not want to repeat. We sell only US-Made Walbro fuel pumps, the best fuel pump on the market in our considered opinion. To find the fuel pump for your car click on the "Find Your Pump" button at left. This will give you not only a great price but will also show you a picture of the pump you will be installing. This will assist you in understanding the installation procedure.
Note: The word bracket used throught these instructions meands pump mounting bracket and fuel level sender assembly.
A) Relieve fuel system pressure.
1) Remove the fuel pump fuse from the fuse block.
2) Start the engine and let it run until it consumed any fuel in the lines and runs out of fuel.
3) After the engine stops, crank it again for at least 3 seconds to assure relief of remaining pressure. (This procedure is necessary since the fuel system can retain gasoline under pressure for a considerable period of time. Opening a pressurized line could spray fuel creating a risk of fire and/or personal injury.
B) Remove the ground (-) cable from the battery and position it so that it cannot accidently make a connection to the battery during the fuel pump replacement procedure.
C) Drain the vehicle tank.
1) First, make sure and appropriate fire extinguisher (Class B - flammable liquids designation, as a minimum) is at hand. Then using an OSHA-approved gasoline transfer pump, remove as much fuel as possible through the fuel tank filler neck. Store the fuel in approved safety containers only.
2) Lift and safely support the vehicle with approved safety stands with enough height to gain adequate access and clearance to remove the fuel tank.
3) As it may not be possible to remove enough fuel from the tank through the filler neck, more fuel may possibly be drained through braket connections once the vehicle is raised.
Note: REGARDLESS of the method used to drain fuel from the tank, it is important to remove as much fuel as possible from the tank before its removal. This is necessary to prevent fuel spillage from being too full or injury from excessive weight while removing the tank.
II. Tank Removal
Warning: It is necessary to obtain help in removing and installing the fuel tank due to its size and weight.
Note: The following are general tank removal instructions and may not be specific enought for your application. It may be necessary for you to refer to the specific service manual for the vehicle you are working on for specific fuel tank removal instructions.
A) Disconnect the electrical connector at the fuel tank to main harness connector, supporting and partially lowering the tank if required.
B) Disconnect any hoses attached between the fuel tank and the vehicle. Be careful when disconnecting fuel lines to avoid fuel spillage. Note all hose connections to make certain hoses are properly reconnected upon installtion.
C) Disconnect and remove fuel filler neck if necessary.
D) Support fuel tank and remove retaining straps to allow tank to be removed from vehicle. Remove the fuel tank being careful to avoid spilling fuel.
E) Note the position and condition of all fuel tank mounting pads and insulators used in isolating the fuel tank from the vehicle body. Mislocated, deteriorated, or incorrect pads and/or isolators can cause objectionable transmission of fuel pump noise into the vehicle.
III. Bracket Removal
A) Thoroughly clean all dirt and debris from the top of the tnak. Clean out any dirt from around the locking ring and retainer. This must be done to prevent dirt or foreign material from falling into the fuel tank while removing the bracket.
B) Remove the bracket retainer with proper service tools.
C) Carefully remove the bracket from the fuel tank. Take care not to bend the float arm or scratch the float when it is removed. Discard the fuel tank to bracket o-ring seal.
IV. Remove And Replace Pump
Replace pump and filter using specific instruction provided with each kit.
V. Installation Of Bracket Back Into The Fuel Tank
A) Inspect the inside of the fuel tank for dirt and debris. If excessive, clean out the fuel tank before installing the bracket.
B) Inspect the bracket to see that it is clean and ready for installtion.
C) Obtain the new fuel tank seal o-ring from the installation kit and place it in the groove at the fuel tank opening. Place the bracket assembly into the tank using care not to disturb the o-ring seal or to hang the float assembly on any protrusions in the tank. Also use care not to fold or twist the filter as this could cause restricted fuel flow. Install the braket retainer.
VI. Install Fuel Tank Into Vehicle
A) Inspect the condition and location of all tank mounting pads, insulators, and brackets. Defective, missing, or mislocated pads and insulators will cause the transmission of excessive noise to the vehicle.
B) Inspect and correct any defects in the fuel hoses, filler neck connections, or similar components related to the fuel tank installation.
C) Install the fuel tank in the vehicle and tighten the tank support strap bolts. Reconnect all lines and hoses and tighten securely. Connect the electrical connections.
D) Make certain that all hoses, fittings, and electrical connections are correctly and securely attached.
E) Make sure that all fuel lines are correctly8 routed and secured in any mounting brackets. Make sure that the electrical harness is installed in the original position and all wire clips and mounting devices are present.
VII. Wrap Up
A) Using only equipment designed for use with gasoline, refuel the fuel tank with gasoline. (Note: Be sure to clean up any fuel spills before proceeding.)
B) Inspect the system for fuel leaks and correct them, if required.
C) With the ignition switch off, install the fuel pump fuse and reconnect the ground (-) cable to the battery.
D) Start the engine and inspect fuel lines and connections for leaks. Correct leaks if any exist.
E) Clear any trouble codes in the electronic control system that may exist as a result of the fuel pump replacement procedure. Use the spcific vehicle service manual for assistance.
Should the pump fail to operate:
Note: This pump will not remedy malfunctions of the regulator, injectors, or other fuel system components.