How to Install an Electric Fuel Pump

This guide will show you how to easily install an electric fuel pump. If the engine receives fuel erratically, experiences low pressure, or doesn’t provide sufficient fuel for combustion, it’s possible that the fuel pump could fail. A bad fuel pump will kill an engine quickly so resolve the issue immediately. As a result of a proper installation, you'll ensure the proper functioning of your vehicle, and will save some serious money along the way.

Tools and Materials Needed:

  • New fuel pump
  • New fuel line, gaskets, seals
  • Hand pump
  • Fuel container
  • Hose
  • Pliers
  • Wrench set
  • Socket set
  • Flathead screwdrivers
  • 2 car jacks
  • Fire extinguisher 

Step 1 – Precautions

Refer to your car's maintenance manual to ensure that the new fuel pump matches with the car’s specifications. Keep any sources of ignition well away from the vehicle, including heaters and electric motors. Work in an open, well-ventilated area and have a fire extinguisher nearby.

Step 2 – Remove the Fuel Pump

In newer cars, the electric fuel tank is located inside the fuel tank. Its access panel is underneath the back seat or in the trunk. Put on your brakes and place bricks in front of the front wheels so that the car won’t move. Remove as much fuel as possible from the tank. Some fuel tanks have a drain plug at the bottom. For those that don’t, insert a hose into the filler neck and use a hand pump to siphon the fuel into a fuel container. Seal the container once all the fuel has been drained from the tank. If necessary, lift the back of the car with a minimum of two jacks for better balance. Disconnect the filler neck from the fuel tank by loosening or removing the clamp that holds the hose onto the tank. Remove the bolts that secure the fuel tank’s straps to the car. Lower one end of the tank. This will allow you to reach the wiring connections, fuel line, and vent hoses on top of the tank. Disconnect the wires and hoses, and use wrenches and pliers to remove the remaining bolts that hold the other end of the straps. The tank can now be removed from the car. Afterwards, unfasten the clamps holding the fuel pump in the place.

Step 3 – Install the New Fuel Pump

If the tank is made of steel and rusty inside, replace it with a new one. Fit the fuel pump properly and tighten. Replace the fuel filter on the pump. Install a new gasket or seal to prevent leaks. Replace the fuel line or vent hoses if they’re old and cracked. Lift the tank high enough so that the fuel pump wires, fuel line, and vent hoses can be reconnected. Install the support straps to hold the tank in the place. Reconnect the fuel filler tube and add fuel to the tank. The tank should be at least 1/4 full for proper fuel pump lubrication and cooling. Start the engine. If you don’t see any leaks, you’ve successfully finished!