Mechanical Repairs

How To Replace Fuel Tanks and Fuel Pumps

Skill Level:
 
 
 
 

Your fuel system houses the life and blood of your vehicle. Unfortunately, the corrosive agents in fuel combined with the wear and tear that come with age can cause your tank and your pump to deteriorate. Thankfully, replacing both of these essential parts is easier than you think.

Remember, if you have any questions or if you're unsure of anything, feel free to contact the Parts Pros at your local PartSource. They're always ready to help, no matter what the job is.

Let's go!

Getting Started

 
Tools You`ll Need:
  • Floor Jack
  • Jack Stands
  • Wrench Set
  • Brass Punch
  • Hammer
  • Suction Pump
  • Torque Wrench
  • 3/8 Ratchet
  • 3/8 Extension
  • 3/8 Socket Set (Comes with ratchet and extension)
  • Gasket Scraper
  • PARTS YOU'LL NEED:
  • Fuel Tank
  • Fuel Tank Straps (only if required)
  • Fuel Pump
  • Fuel Pump Strainer
  • Fuel Filter
  • RTV Silicone

Make Safety Your Top Priority

Every vehicle is different. When it comes to maintenance and repairs, always follow the vehicle's owner's manual.

Safety should be your number one priority. Don't smoke, drink alcoholic beverages, or wear a necktie while working on the car. Watch out for hot objects, sharp instruments, hazardous materials and other potential safety hazards in and around your workspace.

Don't work with a Philips when the job calls for a flat. Substituting tools can compromise your safety or your vehicle's performance.

Finally, when the fun turns to frustration, or if the job requires specialized knowledge beyond your capabilities, please do not attempt it yourself. Talk to a Parts Pro or seek the assistance of a professional mechanic or installer. The last thing we want is someone getting hurt.

Before Getting Started

Since you're working with fuel, a few precautionary steps have to be taken:

-Make sure your work area is well ventilated

-Keep a fire extinguisher handy (just in case)

-Do not even think about smoking

 

STEPS FOR Removing and Replacing the Fuel Tank
  • 1:
    Remove the gas cap to relieve fuel tank pressure.
  • 2:
    Disconnect the negative battery cable.
  • 3:
    Siphon all remaining gasoline out of the tank and into a gas can.
  • 4:
    Raise and support the vehicle on jack stands.
  • 5:
    Disconnect the fuel filler tube.
  • 6:
    If you have an electric pump located in the fuel tank, disconnect the fuel pump harness now.
    You may need to remove the fuel tank shield, equipped on some models.
  • 7:
    Disconnect the fuel return and supply lines.
  • 8:
    Support the fuel tank.

IMPORTANT: If you have access to a transmission jack you can perform the job alone. If not, make sure you have a helper to support the fuel tank.

  • 9:
    Remove the fuel tank straps. Inspect the straps for any corrosion or damage, and replace if worn.
  • 10:
    Lower the fuel tank, and remove.
  • 11:
    Install new tank. Installation steps are the reverse of the removal process.

    See your local PartSource for free print-outs for vehicle-specific instructions, or to purchase a Haynes Manual.
STEPS FOR Installation of Mechanical Fuel Pumps

REMOVAL

  • 1:
    Before you remove or disconnect any lines clean around the lines and the mounting flange. This will prevent any dirt from getting in.
  • 2:
    Remove the supply and replace the fuel lines.
  • 3:
    Cover the line ends after removal to prevent dirt from entering.
  • 4:
    Remove the flange bolts, once you have removed the fuel pump from the engine block, stuff a clean rag in the opening to prevent dirt from entering.

INSTALLATION

  • 1:
    Clean the mounting flange to remove dirt.
  • 2:
    Remove the rag.
  • 3:
    Apply a coat of RTV sealant on the new fuel pump gasket.
  • 4:
    Position the fuel pump flush with the block, and install and tighten the flange bolts.

IMPORTANT : Never force the pump with the flange bolts. If the fuel pump is not sitting flush with the block the rocker arm on the fuel pump is in the incorrect position.

Ask a Parts Pro for torque specifications if you're not sure what torque to tighten the flange bolts.


  • 5:
    Make sure you remove the cover you placed over the ends earlier to keep the dirt out.
  • 6:
    Re-attach the fuel lines.. Start the engine and look for any leaks.
STEPS FOR Installation of Electric Fuel Pumps

REMOVAL

  • 1:
    Disconnect the negative battery cable..
  • 2:
    Siphon any remaining gasoline out of the fuel tank..
  • 3:
    Raise and support the vehicle on jack stands.
  • 4:
    If the fuel pump is located on the bottom of the fuel tank disconnect the supply and return the fuel lines. If the fuel pump is located on the top of the fuel tank, lower the fuel tank slowly after you have the straps removed, and disconnect the supply and return fuel lines.
  • 5:
    Remove the fuel tank.

NOTE: On some models, the fuel pump is on the bottom of the fuel tank. In that case, you don't need to remove the fuel tank. See your local PartSource for free print-outs of vehicle-specific instructions, or to purchase a Haynes Manual.


  • 6:
    Use a brass punch to remove the fuel pump lock ring.

IMPORTANT: Always use a brass punch so there will be no danger of causing a spark and igniting a fire.


  • 7:
    Remove the fuel pump assembly from the fuel tank.

INSTALLATION

  • 1:
    Before you install the new fuel pump o-ring, clean and inspect the seating surface.
  • 2:
    Install the new fuel pump and strainer (also known as a sock filter).
  • 3:
    Use a brass punch and hammer to install the fuel pump locking ring.

NOTE: Most new fuel pumps come with a new strainer. If yours doesn''t, make sure you change the strainer. This will help prolong the life of your fuel pump.



  • 4:
    Install the fuel tank.
  • 5:
    The fuel tank pick-up screen will not filter out the fine particles, so make sure you always change your fuel filter at the specified intervals. This will help prolong the life of your fuel pump.