Replacing a fuel pump, without cutting corners, requires paying attention to detail, using proper procedures, and quality parts for the job. The very first thing to do is to make sure that the fuel system is completely depressurized to avoid fuel spills that could lead to hazardous safety conditions or damage to the vehicle. The Automotive Maintenance and Repair Association-AMRA-states that missing this step increases the chances of fuel leakage by 50%.
After ensuring safety, remove only the components that need to be removed to access the fuel pump. In most vehicles this means removal of the rear seat or the fuel tank. In some vehicles, such as the Chevrolet Silverado, fuel tanks can weigh over 150 pounds and will require appropriate lifting equipment. Most vehicle owners try to save time by not taking the time to properly support and disconnect the tank, which could result in damage to either the tank or its fittings.
Once access is gained, test the performance of the existing fuel pump using a fuel pressure gauge. If the fuel pressure is lower than the manufacturer’s recommended range, typically 40 to 70 psi for most gasoline engines, then replacement is necessary. It is recommended that a replacement Fuel Pump of high quality and meeting the manufacturer’s specifications, be used. As an example, a high-quality Bosch aftermarket Fuel Pump can cost between $150-$300, but using a lower priced, unbranded pump can cut life expectancy by 40% or more and increase the chances of failure.
Replace the fuel filter before installation of the new fuel pump to avoid any debris or contamination being transferred to the new pump. Poor fuel flow caused by a clogged filter can drop as much as 50% and result in poor engine performance. A lot of DIY mechanics overlook this part, which can easily cause the new pump to fail in as little as 6 months. The cost of a new fuel filter ranges from $15 to $40-a pretty small price to pay for keeping the new pump going.
During the installation of the new pump, ensure that all the seals, gaskets, and O-rings are in place for the prevention of fuel leaks. Indeed, according to the Automotive Service Association, 10% of the cases involving improper sealing of the fuel pump result in fuel leaks when fuel pumps are replaced wrongly. Moreover, reconnect the electrical components to the fuel pump carefully. Poor performance or short life of the new pump could be due to improper connections or damaged wiring.
Once the pump is installed and everything is hooked back up, turn the ignition on to test the new pump’s operation and check for fuel pressure. Most mechanics will attach a fuel pressure regulator to set the pressure if it is too high or too low to an optimal setting. A good fuel pump should maintain constant pressure at any time, and the engine should start without any hesitation.
Taking shortcuts to replace the fuel pump will save time or money on the front end but could cost a great deal in the long run. For instance, failing to replace worn-out fuel lines or connectors can result in fuel leakage, which is not only dangerous but could cost upwards of $500 in additional repairs. Similarly, failure to check the electrical connections may result in intermittent fuel pump operation, causing stalling and poor fuel economy, which can cut gas mileage by as much as 15%.
Proper replacement of the fuel pump with high-quality components will go a long way in making the car run smoothly and serve for years to come. For optimal performance, select a replacement Fuel Pump that is at least OEM quality or better to prevent issues down the line. Make your purchase of a reliable Fuel Pump from respected suppliers who have earned a reputation for quality.