Electric fuel pumps are used on all vehicles produced today, because the fuel injection system requires higher pressure than conventional pumps can put out. The pumps are located in the fuel tank and submerged in the fuel. In most vehicles, the fuel pump is integrated with the fuel-sending unit for the fuel gauge. On some trucks, there are two fuel pumps--one pump in the fuel tank and one pump on the frame under the driver's position.

1 Raise and support the vehicle on jack stands. Drain the fuel tank to a low level. This can be done on most GM and Chrysler vehicles by removing the fuel line Schraeder valve and attaching a hose long enough to drain the fuel into a container. Jump the fuel pump relay in the fuse relay box; this will keep the fuel pump on. This concept works on many vehicles, but if it does not apply to the one you are working on, here is an alternate method: Remove the fuel filler hose from under the vehicle at the tank. Insert a fuel hose and drain from there. This is only necessary if there is more than a half tank of fuel. The tank will need to be angled when removing, and if there is too much fuel it will run out the filler openings.

2 Unscrew the screws in the fuel door holding the filler neck to the door. Remove the return line from the fuel tank and loosen the clamp for the filler hose.

3 Disconnect the electrical harness for the fuel pump and fuel level sensor. The connector is either on the rear of the fuel tank or on the driver's side of the tank. If it happens to be one that cannot be accessed at this point, don't worry about it. It will be above the tank and can be removed as the tank comes down.

4 Remove the fuel lines at this point if they are visible on the driver's side of the tank. A few vehicles and trucks have the fuel line connections visible on the side of the tank.

5 Place the floor jack under the fuel tank and raise it enough to support the fuel tank. Remove the bolts in the tank straps that hold the tank in. Lower the tank enough to unbolt and remove the filler hose. Disconnect the fuel line connections on the top of the tank. Disconnect the electrical connector as well if not already done.

6 Lower the fuel tank without tipping it too much and spilling fuel. Use the common screwdriver and the hammer and tap the retaining ring off.

7 Pull the fuel pump and fuel sender assembly out of the access hole carefully so that no pressure is put on the sender rod and float. If it bends, it will not read accurately or may not read at all.

8 Empty the fuel out of the assembly back into the tank before handling the assembly. Remove the sock or fuel filter from the bottom of the fuel pump assembly using the common screwdriver. It is pinched on and must be pried off.

9 Loosen the top clamp on the hose on top of the fuel pump. Unplug and remove the electrical connector from the top of the fuel pump. Pull the bottom of the pump out of its seat and then down to remove it and the hose.

10 Push the new hose on the top of the new fuel pump and tighten the bottom clamp. Put the top clamp loosely on the hose and let it slide down. Pay attention to the fuel pump seat and the bottom shape of the fuel pump. Orient the pump to fit properly into the seat of the housing. Push the top hose on the outlet pipe that it came off of and push the pump upward to install the hose. While pushing up on the pump, push it into the seat in the housing with proper orientation. Move the top clamp up and tighten.

11 Plug in the electrical connector to the pump. Attach the fuel filter, called the sock, to the bottom of the pump. Guide the fuel pump assembly into the tank and orientate the top. There is a tab on the tank that the top of the fuel pump cover must fit in to locate the pump properly. Make sure that the top o-ring is good and in place. If not, replace it with the one that came with the pump. Set the retainer ring on and tap it in place or screw on as appropriate.

12 Install all components in reverse order of removal.

Keyword:electric fuel pump, fuel pump assembly, module