How to Replace a Fuel Pump

If you know that you have a full fuel tank but your engine is not getting any petrol, it might be necessary to perform a replacement of the fuel pump.

Start by parking your vehicle on a solid and level surface and make sure that the parking brake is on. On many vehicles, the electric fuel pump will be located on the fuel tank. Have a friend turn the key into the ON position and listen carefully at the filler opening of the fuel cap. If you hear a humming sound for two or three seconds, the pump is working. If you don’t hear anything, you might need to replace the pump.

The following is a general guide for replacing the fuel pump in all types of vehicles. Make sure to do a bit of research on your particular vehicle model before beginning, to find out if there are any important tips to know about replacing the fuel pump on that specific model.

Safety First

There are a few safety considerations that you should keep in mind before getting started. Before you begin, make sure that you are working within an area that has good ventilation, as you will be working around petrol. Keep any electrical equipment or cigarettes very far away from the area where you will be working. Wear safety glasses and gloves and make sure that you have your fire extinguisher with you. It is also important to use approved petrol storage containers.

Replacing the Fuel Pump - Removing the Old Pump

The first step is to locate and check the fuel pump fuse and relay If you find that this fuse is blown, make sure that you replace it with a fuse of the same amperage. Try your fuel pump again at this point and if it works, you will have solved the issue. However, if not then you will need to replace the fuel pump.


The ground cable will need to be disconnected from the battery’s negative terminal. This is usually a black cable. Next, take a look at your fuel line that is coming from the petrol tank. If it is cracked or leaking, it should be replaced. Make the clamp looser that connects your fuel tank hose to your vapour return hose to the old fuel pump. Once you have disconnected the hoses from the pump, you can plug the end of the hoses with a bolt or a dowel.

The next step is to disconnect your fuel outlet line that goes to your carburettor. You can do this by gripping the fitting of the fuel pump with a wrench while using another wrench to unscrew the nut. Once you have unscrewed the fastening bolts you will be able to dispose of your old fuel pump. Make sure that you discard of it properly in a safe and environmentally friendly way.


Installing the New Pump

Now you can get ready to install the new pump. First of all, make sure that you remove any sealant that remains around the mounting flange. You will then be able to use a new sealer to coat either side of the new gasket. Next, place the fastening bolts within your new pump and make sure the gasket has been fully slid into place.

Make sure that the new pump is positioned correctly The rocker arm should be sitting against your engine’s eccentric gear and the actuating pushrod should be connected to the engine and the fuel pump.


The next task is to make sure that the new pump is connected to the fuel outlet line. To do this, you will need to disconnect the line from the carburettor and then attach the other end with the new pump. Then, reconnect the free end to the carburettor. Remember the way that you used two wrenches to disconnect the fuel outlet line originally? You can use the same technique to tighten the nuts and reconnect the line.


Make sure that the clamp on the fuel tank hose and the vapour return hose are tightened as securely as possible. Next, attach the ground cable to the negative terminal of the battery.

Once you have done this, you can try starting the engine again to make sure that everything is in working order. Check the pump carefully for any leaks. If all goes well, you will have successfully replaced the fuel pump on your vehicle.