How to Install a Fuel Pump on Carsby Contributing Writer
Fuel pumps eventually fail, which can be devastating. Receiving no fuel to the fuel rail is a strong indication that the fuel pump needs to be replaced. Obtaining mechanic services to replace fuel pumps can be costly. Luckily, the Honda car has one of the easier fuel pumps to replace and is possible through do-it-yourself techniques. Replacing the fuel pump in a Honda car consists of using a few basic tools and following specific instructions and using safety procedures. Working outside and in a safe, well-ventilated environment is necessary when attempting to replace a fuel pump. The use of gloves, safety glasses and a fire extinguisher is appropriate.
Under The Hood:
- How to Install a Fuel Pump on a 2004 Dodge Neon
- How to Install a Fuel Pump on a 1989 Honda Accord
- How to Install a Fuel Pump on a 1993 Jeep Grand Cherokee
- How to Install a Fuel Pump in a Porsche 944
- How to Install a Fuel Pump on a 2001 Mazda 626
- How to Install a Fuel Pump on a 2002 Kia Rio
Block the front wheels to prevent rolling. Raise the rear of the Neon with the jack under the rear axle. Place jack stands under both sides of the car just forward of the rear wheels. This will keep them out of the way when dropping the fuel tank. Disconnect the fuel pump harness connector in the rear of the tank.
Loosen the clamps on the fuel filler and vent hose with a screwdriver on the driver’s side of the fuel tank. Place the floor jack under the center of the fuel tank and raise it just enough to touch the tank.
Remove the two bolts in the retaining straps between the fuel tank and rear bumper using a socket. Lower the straps. Lower the fuel tank slowly until the top of the fuel tank can be accessed. Remove the fuel and vent lines by depressing the fittings and pulling them off. Lower the tank to the ground.
Remove the fuel pump retaining cover, which is a round cap that unscrews counterclockwise. If you encounter difficulty in getting it to turn, use a screwdriver positioned on the cap flange and a hammer to tap the screwdriver on the end to loosen the cap enough so that you can remove it. Lift the fuel pump out of the fuel tank taking care not to damage the fuel sending unit float arm.
Remove the fuel level sensor in the bottom of the pump module. Pull the wedge clip out. Disconnect the two wires and push the sensor out of its slot with a screwdriver.
Install the fuel level sensor and plug in the two wires. Push the sensor itself into its slot until it snaps in place. Install the safety wedge by pushing it under the sensor. Install the new O-ring on the lip of the tank opening. Install the fuel pump module orientating the fuel connector connections properly.
Install the fuel pump module cap and rotate it clockwise to tighten it. Place the fuel tank on the jack and raise it enough to engage the fuel lines by pushing them on until they snap in place. Continue raising the tank until the filler and vent hose can be installed. Tighten the clamps with the screwdriver.
Raise the tank until it touches the undercarriage of the vehicle. Install the support straps and tighten the two support bolts with a socket. Connect the fuel pump harness connector. Lower the car to the ground.
Items you will need
Set of sockets
Disconnect the negative battery cable with a 10 mm open-end wrench, a crescent wrench can be used if a 10 mm is not available. Remove the gas cap, to relieve any fuel pressure in the gas tank. Open the cargo area, remove carpet to expose the access cover located in the floor.
Remove the access cover using a Philips screwdriver, revealing the fuel hoses and electric connections. Unplug the electric connection at the pump housing. To ensure the fuel hoses are put back on properly, mark the fuel hoses with tape or a marker. With a pair of needle nose pliers remove the fuel lines.
Remove components slowly as gas vapors are highly flammable. It is a good idea to have a fire extinguisher within arm's reach at all times. Using a 12 mm wrench, remove the nuts that are securing the pump. After all of the nuts are removed, lift the pump from the tank. Be sure to use caution when removing the fuel pump, ensuring not to damage any internal parts.
Compare the new fuel pump for 1989 Honda Accord and compare it to the old pump to ensure the proper pump is installed; compare these prior to installing the new pump. Proceed with installing the new fuel pump, making sure it is correctly seated. Secure the fuel pump into the gas tank with the 12 mm nuts, tightening them evenly to 48 inch-pounds. Reinstall the fuel lines, making sure the clamps are secure. New clamps may be needed if a secure connection cannot be made. Connect the wiring connection at the fuel pump, a click should be heard when fully connected. Reconnect the negative battery cable.
Start the 1989 Honda Accord to ensure proper replacement. Follow by checking for any fuel leaks at the fuel pump. When no leaks are detected, replace the access cover. Tighten the screws with a Phillips screwdriver to 20 inch-pounds. The carpet that was removed earlier can now be put back in the cargo area. Properly discard the old fuel pump.
Items you will need
10 mm open-end wrench
12 mm wrench
Removing the Old Fuel Pump
Detach the ground battery cable (black) using a wrench and loosen the fuel filler cap.
Unscrew the cap from the pressure test port on the fuel rail. The test port is similar to the air valve on your Cherokee tires and is located on the fuel pipe leading to the fuel injectors on the top area of the engine.
Cover the test port with a shop towel and depress the valve with a small flat head screwdriver. Catch the squirt of fuel with the shop towel then replace the cap on the test port.
Siphon the fuel from the fuel tank into an approved container using a hand siphon pump.
Lift the rear of your Jeep using a floor jack. Place a jack stand on each side for support and lower the vehicle.
Loosen the clamps holding the two fuel hoses to the fuel sending unit fittings on the fuel tank using a flat head screwdriver. If necessary, label the hoses before disconnecting them.
Wrap a shop towel around either one of the hoses at the fuel sending unit then pull the hose off the fitting at the fuel sending unit. Use the shop towel to absorb any residual fuel in the hose.
Unplug the wiring harness electrical connector from the fuel sending unit.
Rotate the retaining locking ring on the fuel sending unit counterclockwise using a brass punch and hammer until the ring is free.
Lift the fuel sending unit off the fuel tank and remove the O-ring seal under the unit’s flange.
Remove the fuel sending unit from the Jeep and detach the fuel pump wires from the unit.
Loosen the pump hose clamp at the fuel sending unit using the flat head screwdriver then detach the hose from the unit.
Unscrew the top bracket nut holding the pump to the fuel sending unit then remove the fuel pump from the unit using a ratchet and socket.
Installing the New Fuel Pump
Place the new fuel pump in position in the fuel sending unit then tighten the top bracket nut using the ratchet and socket.
Connect the pump hose to the fuel sending unit and tighten the clamp using the flat head screwdriver.
Attach the fuel pump wires to the unit.
Place a new O-ring seal on the fuel tank opening.
Install the fuel sending unit in the tank and rotate the retaining locking ring clockwise with the brass punch and hammer until the ring hits the stops.
Plug the wiring harness electrical connector to the fuel sending unit.
Attach the fuel hoses to the fuel sending unit and tighten the clamps using the flat head screwdriver.
Lower the Jeep with the floor jack.
Refill the fuel tank.
Reattach the ground battery cable (black) using the wrench then retighten the fuel filler cap.
Start the engine and check for fuel leaks at the tank.
Items you will need
Flat head screwdriver
Hand siphon pump
Jack stands (2)
New O-ring seal
Disconnect the cable that goes to the negative terminal on the battery. Loosen the lug nuts on the rear, passenger-side wheel. Lift the rear passenger side of the 944 with a floor jack. Lower it securely onto a jack stand. Finish removing the lug nuts and the wheel.
Locate the fuel pump. This is a small cylindrical device with fuel lines and electrical connections coming off it. Loosen the nuts holding the wires to the fuel pump with a wrench. Note which terminal each wire goes on.
Place a pair of vice grips on the fuel line that comes from the tank and goes into the fuel pump. Place another pair on the line that goes from the pump to the engine. The line just has to be squeezed enough to prevent the fuel from coming out when you remove the fuel pump. Use a rag between the vice grips and the fuel line to prevent damage. Place a tray under the fuel line to catch any fuel that does spill.
Loosen the hose clamp that holds the fuel line to the fuel pump. Pull fuel lines off either end of the fuel pump. You may need to push on the lines with a screwdriver to free them if they are stuck to the pump.
Loosen the bolt on the bracket that holds the fuel pump to the chassis with a wrench or a socket and ratchet. Remove the fuel pump from the bracket.
Install the new fuel pump into the bracket. Tighten the bolt that holds the bracket in place on the car. Install the wires on the proper terminals and tighten the nuts. Slide the fuel lines back onto the fuel pump at either end. Tighten the hose clamps.
Remove the vice grips from the fuel lines. Reinstall the wheel. Lower the car off the jack stands. Tighten the lug nuts by hand. Reconnect the cable to the negative battery terminal. Start the engine and check for fuel leaks.
Items you will need
Socket set and ratchet
Vice grips (2 pair)
Park the vehicle on a level surface and set the parking brake. Open the vehicle hood and support it with the hood prop rod. Install the 9-volt battery to the memory saver and plug the memory saver into the cigarette lighter socket. Disconnect the negative battery cable from the battery with the socket and ratchet. Open the relay center that is between the battery and strut tower on the left side of the engine bay. The fuel pump relay is in the third row of relays from the strut tower and it is the second relay from the driver's side in that row.
Start the engine and allow it to run until it stalls out and then crank it for an additional 10 seconds to relieve the fuel pressure. Turn the ignition key to the “Off” position. Remove the gas cap to relieve any fuel vapor pressure.
Place the wheel chocks around the front wheels. Lift the rear of the vehicle into the air with the floor jack and place the jack stands under the rear suspension. Lower the floor jack until the vehicle rests securely on the jack stands. Remove the floor jack.
Place a 5-gallon gas can directly under the fuel fill door. Install one end of the siphon pump into the fuel filler neck and direct the other end into the 5-gallon gas can. Siphon as much fuel from the tank as possible, making sure not to over fill each gas can. Store the removed fuel in a safe place for later use.
Lie down under the vehicle and look to the front of the tank to locate the fuel line connections. Squeeze the plastic tabs for each fuel tank line and separate the sending and return lines from the fuel tank lines. Disconnect the wiring harness from the fuel pump connector. Squeeze the pressure clamp for the fuel filter neck and no return valve and slide the clamp away from the tank. Remove the fuel filler neck, no return valve and the evaporative emissions vent hose.
Place the floor jack directly under the fuel tank and raise the jack arm until there is just enough room to fit the block of wood between the tank and the jack arm.
Place the block of wood between the tank and jack arm. Raise the jack arm until the wood makes contact with the fuel tank and shield, but do not apply any additional pressure. Instruct the helper to hold the fuel tank in place. Remove the tank strap bolts with the socket and ratchet. Swing the tank straps down and remove them from under the vehicle.
Instruct the helper to balance the tank on the floor jack while the fuel tank is lowered from its position under the vehicle. Remove the fuel tank and shield from the block of wood and jack. Slide the fuel tank and shield from under the vehicle.
Squeeze the plastic quick connectors securing the fuel tank lines to the fuel pump inlet and outlet hoses, then disconnect the fuel tank hoses from the fuel pump. Remove the screws securing the fuel pump to the fuel tank with the ratchet and bit-driver attachment. Lift the fuel pump out of the fuel tank and discard its mounting gasket.
Place the new fuel pump mounting gasket onto the fuel tank opening. Line up the holes in the gasket with the threaded holes in the fuel tank. Set the new fuel pump into position. Install the mounting screws and tighten to 10 to 19 inch-pounds with the inch pounds torque wrench and bit driver.
Slide the fuel tank under the vehicle. Place the block of wood and floor jack under the fuel tank mounting location. Lift the fuel tank onto the block of wood and jack arm with the assistance of your helper. Instruct the helper to maintain the tank balance and lift the fuel tank into position with the floor jack.
Hook the fuel straps into position on the front side of the tank and shield, and swing them into position at the rear of the tank. Install the tank strap bolts and tighten to 32 to 44 foot-pounds with the torque wrench. Lower the floor jack and block of wood.
Install the new fuel line retainer clips onto the fuel pump connections by sliding them over the fuel lines on the fuel pump. Clip the sending and return lines into place on the fuel pump. Install the fuel filler neck and no return valve, and then install the clamps. Install the evaporative emission lines to its respective connection.
Lift the rear of the vehicle off of the jack stands with the floor jack and remove the jack stands. Lower the rear of the vehicle to the ground and remove the floor jack.
Fill the fuel tank with the gas that was removed previously and stored in gas cans. Install the fuel filler cap and tighten until it clicks three times.
Inspect the socket for the fuel pump relay and locate terminal number 30, which is the bottom left terminal. Connect the jumper wire to terminal 30. Loosen the body ground on the core support near the hood latch with the socket and ratchet. Install the opposite end of the jumper wire to the body ground and tighten the ground bolt snug with the socket and ratchet.
Connect the negative battery cable to the battery and tighten the terminal with the socket and ratchet. The fuel pump will turn on as soon as the negative battery terminal is connected to the battery. Allow the fuel pump to operate continuously for the next five minutes. While the fuel pump is running inspect the fuel system for any leaks and replace any leaking lines or hoses as necessary.
Loosen the body ground at the core support with the socket and ratchet. Remove the jumper wire from the body ground. Tighten the body ground bolt snug with the socket and ratchet. Disconnect the jumper wire from fuel pump relay socket 30.
Install the fuel pump relay. Install the fuse center lid and shut the vehicle hood.
Items you will need
5 Gallon gas can (up to 4 needed)
Block of wood
New fuel pump gasket
Fuel line retainer clips
Open up the rear doors and reach in between the seam between the top of the back seat and the bottom. Unbolt the lower seat cushion from the chassis using the 3/8-inch ratchet and socket. Pull the bottom cushion away from the chassis and set it outside the vehicle.
Open the gas door and remove the gas cap. Unbolt the silver fuel pump cover from the chassis using the 3/8-inch ratchet and socket. Unplug the electrical connection to the fuel pump with your hands. Put the key in the ignition and attempt to start the car. If it starts, allow it to run until the engine dies. Then remove the key from the ignition.
Disconnect the fuel line connections to the fuel pump, using a pair of pliers. Then pull the fuel pump and bracket assembly out of the gas tank. Pull the stock seal off the gas tank with your hands. Set a replacement seal onto the tank, then install the replacement fuel pump in the tank. Reconnect the fuel lines to the fuel pump, using the pliers.
Connect the electrical connection to the fuel pump, using your hands. Then bolt the silver cover to the chassis with the 3/8-inch ratchet and socket. Reinstall the rear seat cushion, using the ratchet.
Items you will need
Open-end wrench set
3/8-inch ratchet and socket set
Replacement fuel pump
Replacement seal ring