How to Remove the Fuel Pump From Cars

by Contributing Writer

Caterpillar, also known as CAT, has been manufacturing heavy-duty diesel, natural gas and gasoline engines for more than 80 years. When fuel isn't getting to the engine, the fuel pump is often to blame. The pump pulls fuel from the tank and sends it through the fuel line toward the engine. The fuel is injected into the engine, where it is combusted to fire the pistons and power the engine of the Caterpillar 3406.

Under The Hood:

 How to Remove a Fuel Pump in a 1997 Mercury Grand Marquis

Raise the hood to access the engine compartment. Disconnect the negative terminal from the battery.

Locate the drain plug at the bottom of the fuel tank. Open the drain plug with a crescent wrench. Allow all the fuel to drain into a large drain pan. Tighten the plug when the tank is drained.

Raise the back end of the vehicle by placing a jack under the driver's side rear door. There is an indented spot that is braced for the weight of the car. Chock the front wheels to ensure the car does not roll while lifted. Set the parking brake.

Place a second jack under the fuel tank to prevent the tank from falling to the ground when the straps are removed. Ensure the jack is in the center of the tank.

Unbolt the two straps with a socket wrench. Place the straps out of the way once they are removed.

Rest the tank onto the jack. Lower the tank enough to access the fuel lines and electrical wires. Separate the fuel line from the top of the tank by pulling the tabs then pulling away from the piping that holds the line in place. Disconnect the electrical lines from the tank by pushing down on the locking tab at the connector and pulling off from the connecting harness.

Slide the tank out from underneath the car. Lower the car until you are ready to install the tank.

Twist off the cap at the top of the gas tank with a counterclockwise movement using a large set of channel locks. Place the cap to the side and discard the O-ring.

Lift up on the fuel pump assembly to pull it out of the tank. You may have to tilt the assembly to pull it out comfortably.

Items you will need

  • Jacks (2)

  • Wheel chocks (2)

  • Crescent wrench

  • Drain pan

  • Socket set

  • Socket wrench

  • Channel locks

  • Hammer (optional)

  • Flat head screwdriver (optional)

 How to Remove the Fuel Pump On the Pontiac Montana Van

Disconnect the negative cable from the negative battery terminal in the engine bay of the Pontiac Montana. Open the fuse box. Check the diagram on the undercover of the fuse box for the position of the fuel pump fuse. Pull out the fuel pump fuse.

Siphon the gas from the fuel tank via the gas filler neck on the driver's side of the Pontiac Montana.

Raise the Montana with your jack and tire iron. Position a jack stand near the rear axle under the chassis. Lower the Montana onto the jack stand. Repeat this process on the other side of the van.

Remove the filler hose from the gas tank. Loosen the collar on the filler hose with a screwdriver. Slide the collar away from the fitting of the hose. Pull the hose off of the gas tank. Repeat this process for the vent hose.

Set the floor jack below the gas tank. Loosen the engine-side strap that holds the gas tank against the Montana's chassis. Let the gas tank rest onto the floor jack.

Reach above the gas tank. Disconnect the EVAP tube, return fuel tube, and wiring connector from the fuel pump.

Loosen the second strap to let the gas tank rest fully on the floor jack. Push the floor jack out from below the Montana.

Spray the surface around the gas tank with compressed air to remove contaminates near the opening of the gas tank.

Loosen the metal locking ring cinching the fuel pump by striking the tabs of the ring with a mallet and chisel. Pull the ring off of the fuel pump. Lift the fuel pump out of the gas tank.

Items you will need

  • Hand siphon pump

  • Gas cans

  • Jack

  • Tire iron

  • Jack stands

  • Socket wrench set

  • Screwdriver

  • Compressed air

  • Rag

  • Mallet

  • Chisel

 How to Remove the Fuel Pump on a 2003 Impala

Relieve the fuel system pressure. Open the gas filler cap. Pull the fuel pump relay out of the junction box on the right side of the engine compartment. The inside of the lid shows the location of the relay. Start the car and run it until the engine dies. If your fuel pump is completely dead and the engine won't run, then the pressure is already relieved from those lines.

Remove the spare tire and trunk liner to reveal the fuel pump access panel. Remove the seven nuts that hold it in place and pull off the panel.

Unplug the electrical connector and wipe off the pipes and assembly to prevent buildup from getting into the fuel. Snap open the quick-connect fittings and remove the hoses.

Pry off the snap ring that retains the pump and slide the pump assembly out of the tank.

Items you will need

  • Socket wrench

  • Socket set, metric

 How to Remove the Fuel Pump From a Caterpillar 3406

Place the fire extinguisher nearby in case of accidental fuel ignition.

Follow the fuel line from the fuel tank to the fuel pump attached to the engine.

Detach the circular clamps on the fuel line. Take note of the "in" (from the tank) and the "out" (to the engine) directions of the pump. Pull the fuel hoses off. Clog the holes in the line with pieces of rag so debris stays out of the line and the fuel doesn't spill.

Remove the mounting bolts with the socket wrench.

Remove any gaskets and scrape off any gasket residue.

Bolt the new fuel pump in place and reattach the fuel lines. Be sure to push the fuel lines over the hose lips on the pump. Tighten the hose clamps. Turn on the engine to test the pump. Be sure fuel is making it to the engine.

Items you will need

  • Socket wrench

  • Socket set

  • Screwdriver

  • Rags

  • Fire extinguisher

 How to Remove a Fuel Pump From an Oldsmobile Silhouette

Raise the front of the vehicle with the floor jack and support it on jack stands situated on the frame to prevent interference with the removal of the fuel tank. Unplug the electrical connectors located to the rear of the fuel tank. Loosen the hose clamps on the filler tube with a screwdriver. Remove the tube.

Loosen the clamp on the vent tube, which parallels the filler tube, at the point of connection at the tank. Pull the hose off at the tank and just move it aside. Remove the metal fuel tank shield bolts, and ultimately the shield, with the use of a ratchet and the appropriate-size socket.

Position the floor jack under the fuel tank between the support straps. Remove the two strap-securing bolts located in the cross brace behind the tank, using a ratchet and a 15mm socket. Lower the straps and push them to the front of the tank to prevent interference.

Remove the nylon purge hose from the charcoal canister behind the tank. The hose has a quick-disconnect at the canister, which requires nothing more than squeezing the connector and pulling it free. Lower the fuel tank slowly, just enough to reach the nylon hose connectors on the top of the tank connected to the top of the fuel module. Remove the fuel-supply and fuel-return lines' quick-disconnect fittings.

Unplug all electrical connections to the fuel pump, sending unit and fuel tank pressure sensor. Remove the tank from under the vehicle.

Loosen and remove the lock ring from the top of the fuel module. The lock ring has the appearance of a circular sprocket with a series of square tangs around the circumference. The fuel tank also has a set of corresponding tangs. When locked in place, the tangs on the lock ring engage the tangs on the fuel tank. To remove the lock ring, place a screwdriver on one of the vertical tangs deliberately placed over the horizontal tangs for use as a means of removal. Tap the vertical tang in a counterclockwise direction with the hammer to unlock the tangs.

Lift the fuel pump module up and out of the fuel tank. Keep the module over the opening in the tank and carefully empty the fuel that is captured in the module back into the fuel tank.

Items you will need

  • Floor jack

  • 2 jack stands

  • Ratchet

  • Set of sockets

  • Common screwdriver

  • Hammer

 How to Remove a Fuel Pump From a 2003 Oldsmobile Alero

Lower the vehicle's fuel level. If the vehicle is operational, run the engine. Run until the fuel level drops to less than 1/8 of a tank. The reason for this is because the fuel pump is located inside the fuel tank, so you don't want a lot of gas in the tank when working on it.

Raise the vehicle. Use the floor jack to raise the vehicle to a comfortable level so you can easily perform the procedure. Place the vehicle securely on jack stands.

Remove the fuse in the fuel pump. Locate the fuel pump's fuse. There should be a diagram on the inside of the fuse box cover. With the engine running, remove the fuse. Once the fuse is removed, the engine should shut off from lack of fuel. This lets you know that you have pulled the proper fuse and there is no more fuel under pressure in the fuel lines. Shut off the ignition.

Disconnect the car's negative battery cable. This should be clearly marked on the battery and is normally the black connector.

Disconnect and lower the fuel tank. Make sure the fuel tank is safely supported from below with the floor jack. Slowly and carefully lower the tank, using the floor jack. You must be able to comfortably access and disconnect the fuel lines from the top of the fuel tank.

Remove the fuel tank sending unit from the fuel tank. The fuel pump is located within the sending unit. Remove the sending unit by turning and carefully lifting the unit out of the gas tank. Use caution around the O-ring seal.

Remove the fuel pump from the sending unit. The fuel pump is rubber-mounted and should easily come out.

Items you will need

  • Floor jack

  • Jack stand

  • Wrench set

  • Safety glasses

 How to Remove the Fuel Pump on a Buick 3.8 Liter V6 Engine

Park the car on a flat and level surface. Ensure the front wheels are chocked from the front of the car.

Place a jack under the rear axle beam and raise the car up to make more room to work. Place jack stands under both sides of the vehicle under the axle beam. Lower the car on to the jack stands.

Locate the fuel tank under the trunk of the car. The fuel tank has two straps holding the tank in place.

Place the jack underneath the fuel tank. Raise the jack up to the fuel tank. This will make removing the fuel tank easy when the straps are removed.

Unbolt the straps with a socket wrench. The straps have two bolts per strap.

Lower the tank slightly to access the fuel hoses at the top of the tank. Unscrew the hose clamps with a flat tip screwdriver. Disconnect the electrical connectors and the vacuum hoses.

Unscrew the hose clamp on the fuel filler hose at the back of the tank. Pull the hose off the back of the tank.

Lower the tank down to the ground. Pull it out from under the car.

Tap the protruding tabs at the top of the tank counterclockwise with a flat tip screwdriver. Push the retaining ring until it is freed from the tank.

Pull the fuel pump out of the tank by pulling it up. Remove at an angle to clear the float at the bottom of the pump assembly.

Items you will need

  • Jack

  • Jack stands

  • Socket wrench

  • Socket set

  • Flat tip screwdriver

  • Hammer

 How to Remove the Fuel Pump in a 1998 Ford Escort

Pop the hood of your Escort. Attach the fuel pressure gauge to the Schrader valve, which is located on the end of the fuel rail. Press the pressure relief valve on the pressure gauge to release the fuel pressure in the system.

Unbolt the bottom of the rear seat at the leading edge of the seat using the 3/8-inch ratchet and socket. Lift the seat base up and out of the rear of the car. Unplug the harness to the fuel pump underneath the seat, then unbolt the cover to the pump using the 3/8-inch ratchet and socket. Unbolt the ground strap for the pump with the ratchet as well.

Disconnect the quick-connect fuel lines from the fuel pump by hand. Remove the locking ring on the top of the fuel pump using the brass drift and the hammer to knock the ring off of its mount.

Lift the fuel pump out of the tank, making sure not to drip gasoline on the interior of the car.

Items you will need

  • Fuel pressure gauge

  • 3/8-inch ratchet and socket set

  • Brass drift

  • Hammer

 How to Remove the Fuel Pump in a 1993 Ford Probe

Removing the Fuel Pump

Park your Probe on a level surface. Start the engine and apply the parking brake.

Open the hood and remove the lid from the fuse box located in the left side (driver side) of the engine compartment. Then remove the fuel pump relay. The inside of the lid has a diagram for you to locate this relay.

Replace the fuel pump relay once the engine stalls. You have just released the pressure from the fuel system. Now turn off the ignition key.

Detach the ground (black) battery cable using a wrench.

Open the driver and passenger doors. Push on the clips located at the bottom on each side of the rear cushion and remove the cushion.

Locate, on the rear floor, the electrical connector going through an access cover and unplug the connector. This connector goes to the fuel pump/sending unit assembly inside the fuel tank.

Unscrew the access door using a ratchet, ratchet extension and socket and move the access cover to the side.

Detach the fuel hoses from the fuel pump/sending unit assembly using a pair of slip joint pliers.

Unscrew the fuel pump/sending unit assembly from the fuel tank using the ratchet, ratchet extension and socket.

Lift carefully the fuel pump/sending unit out of the tank and discard the fuel pump tank seal.

Unplug the fuel sending unit electrical connector. After that, unscrew the sending unit mounting nuts using the ratchet and socket and remove the sending unit from the fuel pump assembly.

Installing the New Fuel Pump

Install the sending unit on the new fuel pump assembly using the ratchet and socket. Now plug the sending unit electrical connector to the fuel pump assembly.

Set the fuel pump/sending unit in the tank using a new fuel pump tank seal.

Screw the fuel pump/sending unit assembly to the fuel tank using the ratchet, ratchet extension and socket.

Attach the fuel hoses to the fuel pump/sending unit assembly using the slip joint pliers.

Set the access door in place and plug the electrical connector to the fuel pump/sending unit assembly. But do not install the mounting screws yet.

Attach the ground (black) battery cable using the wrench. Start the engine and check for fuel leaks at the fuel hoses attached to the fuel pump/sending unit assembly. After that, turn off the engine.

Install and tighten the mounting screws to the fuel pump/sending unit access door.

Set the rear cushion in place and push the cushion under pins against the retaining clips on the floor so the clips catch on the cushion pins.

Items you will need

  • Wrench

  • Ratchet

  • Ratchet extension

  • Socket

  • Slip joint pliers

  • New fuel pump tank seal

 How to Remove a Fuel Pump From a 2001 Ford Excursion

Park the Excursion on a level surface and apply the emergency brake. Put on goggles and work gloves. Fuel can spray from the pressurized lines and get in your eyes, causing serious injury. Remove the fuel pump fuse, located in the main fuse box in the engine compartment of the truck. Start the vehicle and wait until the engine stops. This will drain excess fuel from the lines and reduce spillage.

Remove the negative battery cable from the negative battery terminal to prevent accidental electrical shorts or injury to yourself. Set the cable down so that it cannot touch metal or any part of the frame of the truck.

Remove the fuel lines from the fuel pump. There may still be some pressure in the lines, so use caution and plug the opening in the hose with a cork or rubber stopper. Remove the mounting bolts that secure the fuel pump, using a socket wrench. If the bolts are rusted or stuck, use a generous portion of the PB Blaster Penetrating Lubricant and let it soak onto the bolts. Tap the bolt heads a couple of times with the wrench to let the lubricant work its way into the bolt threads. Lift the fuel pump from the engine block and make sure that the small gaskets don't fall from the pump into the engine.

Clean any broken pieces of the gasket from the engine block with a rag. Apply gasket sealer on the area of the old gasket and install the new gasket. Set the new fuel pump over the gasket and re-bolt it to the engine block. Apply anti-seize spray to the bolts to ease future removal of the new fuel pump. Tighten the bolts and reattach the hoses to the pump.

Reconnect the negative battery cable to the negative battery terminal, then reinsert the fuel pump fuse and start the Excursion. Examine the new fuel pump closely for leaks from the hoses or the rest of the fuel line. Listen as the pump runs for the squeaking noise that indicates it is working. Test drive the truck on a short trip to see if there is any hesitation or problems like those you had before you replaced the fuel pump.

Items you will need

  • Replacement fuel pump

  • Replacement gasket

  • Rag

  • Goggles

  • Gloves

  • Cork or rubber stopper

  • Ratchets

  • Wrenches

  • PB Blaster Penetration Lubricant

  • Gasket sealer

  • Anti-seize spray