How to Change the Fuel Pump in a 1996 Buick Regalby Kyle McBrideUpdated November 07, 2017
Items you will need
Flare-nut wrench set
Hammer (brass, leather, rubber or wood)
The 1996 Buick Regal came equipped with a throttle body type injector system. Fuel is delivered to the high-pressure injectors from the fuel tank by a low-pressure/high volume, diaphragm type, positive displacement electric fuel pump that is mounted inside the gas tank. Fuel pump failure can be caused by a breakdown in the electric fuel pump motor or a failure in the rubber diaphragm. Symptoms of a bad fuel pump can be created if the fuel pump relay or the fuel pump fuse is burned out. These components are easily checked and should be eliminated as possibilities before you go through the process of removing the fuel pump.
Remove the Gas Tank
Remove the fuel filler cap to vent any pressure in the tank to the atmosphere. Remove the fuel pump fuse from the fuse box.
Start the engine and run it until it dies. Turn the engine over with the key for three seconds. Turn the key off.
Disconnect the negative battery cable with a wrench.
Siphon as much fuel from the tank as possible with a siphon kit.
Chock the front wheels with wood blocks. Raise the rear of the vehicle with a jack and support the vehicle with jack stands.
Disconnect the connector block for the fuel gauge sending unit and the fuel pump power supply located at the front of the tank by hand.
Disconnect the filler neck, vent, fuel feed, fuel return and fuel vapor tubes from the tank. Squeeze the tabs on the plastic retainer clip by hand and pull the lines off. Loosen the pressure fittings with a flare nut wrench and a backup wrench. Inspect the o-ring on the pressure fitting and replace if necessary.
Remove the rubber exhaust hangers and remove the exhaust pipe and heat shield with wrenches, if necessary. Remove both fuel tank retaining straps with a wrench. Carefully lower the fuel tank away from the vehicle.
Replacing the Fuel Pump
Tap carefully on the tabs of the lock ring with a punch and a hammer (preferably made of brass and rubber) respectively, and rotate the ring counterclockwise until the tabs align with the slots in the fuel tank to unlock the fuel pump.
Lift the pump up and out of the tank. Use caution when handling the fuel level float and the fuel level sending unit as they are delicate and easily damaged.
Inspect the rubber sealing ring around the locking mechanism. Replace the ring if it appears damaged or deteriorated before installing the new pump.
Guide the new pump into the tank and push the pump against the tank to compress the sealing ring and allow the locking ring to engage in the tabs. Tap the ring into the locked position with the hammer and punch.
Reverse the removal process to finish installation.
Use caution when working with the fuel system. Gasoline is extremely volatile, and the fumes are explosive. Perform this work either outside or in an area with ample ventilation. Do not work on the fuel system in an enclosed building with natural gas fixtures in it, or the pilot light may cause an explosion. Use a brass punch and a brass, rubber, leather or wooden hammer to remove the locking ring. A spark can be generated if steel tools are struck together, which can cause an explosion.
If your Regal is equipped with an anti-theft system, disable the lockout feature before disconnecting the battery cable.