Fuel Pump Replacement – Sydney Car Repair

What is a fuel pump?

In the days before fuel injection, the fuel pump was a mechanical component located in the engine bay which often used the movement of the engine itself to pull fuel from the tank to the carburettor.

With the advancements in electronic fuel injection and electronic engine management, the fuel pump evolved into an electric pump located in the fuel tank. When the ignition is switched on, battery power is sent to the fuel pump, which operates for 3-4 seconds to build fuel pressure in the fuel lines. When the engine is cranked over, this pressure allows the engine to start and the fuel pump continues to supply fuel to the engine to keep it running.

When the ignition is switched on, battery power is sent to the fuel pump, which operates for 3-4 seconds to build fuel pressure in the fuel lines.

When the engine is cranked over, this pressure allows the engine to start and the fuel pump continues to supply fuel to the engine to keep it running.

Symptoms you may need to have your fuel pump replaced

Vehicle cranks over but does not start

Engine hesitates under acceleration

Check engine light is on

Reduced performance and increased fuel consumption

Can I carry out a fuel pump replacement myself?

A fuel pump replacement is a tricky job – especially if you have just filled your tank! Requiring the removal of the fuel tank before beginning the repair using multiple jacks and elevation, a DIY mechanic may not have these available. As well as the usual problems, there is the complication of fuel being flammable. This task could be dangerous for a non-professional, so we recommend leaving this one to the trained mechanics. If you do attempt the replacement yourself, have a fire extinguisher to hand and ensure the space around you is well ventilated so and fuel fumes can blow away.

What additional factors could affect fuel pump replacement?

Usually, the cost of replacing a fuel pump is down to the make and model, whom you choose to do the work and where in the country you are based, yet there are a few circumstances that could bump up the price:

Whether the issue is with the armature or the physical pump itself 

Discovering further damage within the engine -due to driving with a faulty fuel pump for too long

Availability of spare parts 

Some fuel pumps require parts to transfer from the old unit; this can be problematic if they are damaged

How long does a fuel pump repair take?

We found that the average fuel pump replacement job can take anywhere between 1 and 6 hours.

Engines vary between different car makes and models, as does the time this repair takes. This variation can be due to the construction of the vehicle. For example, in a Land Rover Defender, there is no easy access to the top of the fuel tank, which contains the fuel pump. Therefore the time taken will lie closer to 6 hours. On the other hand, most Honda models have easy access, making them quicker to repair.

How can I carry out a fuel pump repair?

Without appropriate experience and safety equipment, you should never carry out the fuel pump replacement yourself. In this case, a local garage is the better option, especially since this is a simple routine job for a technician (but will not be a novice DIY project), potentially saving you precious time and money.

Replacing a fuel pump won’t look the same for every vehicle, but these basic steps are a good place to start. 

First, make sure your vehicle doesn’t have an access panel that will allow you to access the pump without removing the tank. We’ll show you what to do if you do need to drop the tank. 

Safety first

We always put safety first, so make sure you’re thorough and careful. Don’t forget to wear safety glasses and gloves. Give yourself room to work and have cleanup materials ready to clean any spills immediately. Work in a well-ventilated area away from an open flame or anything that could cause a spark or ignite fuel, such as pilot lights and incandescent light bulbs. Make sure you have a fire extinguisher on hand. Don’t smoke, either. Always relieve fuel pressure prior to opening fuel systems because releasing fuel under pressure can cause fire and injury. Store fuel in an approved container like a gas caddy or gas can. 

Tools Required 

      – Replacement fuel pump 

      – Wrenches

      – Several jacks 

      – Platform lift 

      – Siphon pump 

      – Rags 

      – Car manual

Procedure for replacing your fuel pump 

First, you’ll need to lift the vehicle so you can remove the tank. If there’s gas in the tank, you’ll have to drain it into an approved container first. 

It’s important to clean the tank thoroughly during the repair. 

Next, remove the clamps from the fill lines and then remove the fill lines as you prepare to drop the gas tank. You can use a rag to avoid getting dirt in the tank. Make sure to support the tank as you remove the straps and carefully lower the gas tank. 

Next, you’ll need to disconnect the wire connectors and fuel lines that connect to the module. Clean the top of the tank, and then remove the pump retaining ring. 

Remove the pump assembly so you can replace it with a brand-new part. Keep in mind that some fuel pumps require parts to be transferred from the old unit. 

And then you just need to reverse the procedure. Get the pump installed and the pump retaining ring back in place and raise the tank close to the vehicle so you can reconnect the wire connectors and fuel lines. Reconnect the straps and fill lines with the tank properly positioned. Partially fill the tank and run the vehicle so that you can inspect for any leaks. 

And you’ve done it. Just be careful and follow safety precautions and you can be back on the road in no time. Don’t forget to replace the fuel filter as well so that your new pump will run smoothly.