How to Replace Fuel Pumps with Access Panels

A step by step guide of how to replace fuel pumps with access panels as opposed to having to remove the fuel tank from the vehicle. A safer and more effective fuel pump repair job begins here.




Hi everyone. Welcome to the Delphi How To Series videos. I’m Clay Pennington, Senior Product Specialist here at Delphi Products and Service Solutions. This video, we show you how to replace a fuel pump when you have an access panel instead of having to drop the tank. Make sure you follow all safety precautions and have safety glasses and gloves on hand. You have to relieve the fuel pressure first, so I went ahead and disconnected my electrical fuel pump connector and cranked the motor until the fuel pressure died off and the car died out. Fuel pressure is relieved. I’m going to go in there now. I’ve cleaned off around the outside a little bit. I’m going to now disconnect the fuel lines.

Okay, so now we’re ready to access the retaining ring. You want to make sure it’s clean on the top of the pump, and we use a little compressed air just to make sure there are no dirt balls in the tank. Now that we’ve got this retaining ring loosened up, we’re ready to remove it and pull the pump out. Retaining ring is out, ready to lift the pump out. There’ll be some fuel coming up with this fuel pump, especially if there’s a lot of fuel in the tank. In this case, it’s pretty full, so kind of maneuver the pump out of here without making that big of a mess and have a container ready to catch the rest of this pump fuel in. Tight fit but ready to come out. Just make sure you watch for the strainer. Make sure you’re watching the fuel level arm. Here we go. Fuel pump’s out.

This one’s got a square O-ring instead of round, so just keep an eye on that. We’re all set. We’ll clean it up and then get ready to put the new one in. Okay, so now we’re ready to drop this new pump back in the tank. I’ve got the tank area cleaned up, got a new O-ring in place. I transferred over the fuel line retainers from the old pump. They have to go with the new one to hold the fuel lines on. Had to transfer those over. Some pumps you have to transfer them over, just watch what you have to do, so I’m going to go ahead and put the O-ring on, and we’ll slip the pump back in place. Make sure your guide sending unit is on in place first and watch everything else go in.

If you’ve got that securely put in place, make sure it fits down all the way in. We can move on to putting our retaining ring on. Now, we’ve got the retaining ring back in place. We’ll go ahead and snap these fuel lines in place. After that, some pumps require new electrical connectors depending on the design. This one requires that old style with a square 4-pin. The new style is the inline 4-pin. We’re going to have to transfer that over. Look at one of our other videos on how to do that. I’m going to go ahead and snap these fuel lines back in place here and then check for leaks.

Make sure those lines are securely snapped in place and the retainer is in place, and we can ensure a leak-free connection. Once we splice in this new electrical connector, we have to heat shrink these heat-shrinkable connectors that have glue inside them. Once we heat shrink those down with a heat gun, not a hair drier, not an open source flame, because gas fumes may be around. Glue will come out of that connector and make that sealed connection and last a very long time. Okay, so now we’ve finished up with this wiring connector on this vehicle. If the pump needs a new connector and comes with it, it’ll come with a set of instructions on how to wire it up. Now, we just fire up the pump, check for leaks, wrap up by putting on the cover, and we’re good to go. Now you’ve done it. Be sure to follow all safety precautions, and you’ll be back on the road in no time. Make sure to check out more of our Delphi How To Series videos. It’ll help save you time in your shop every day.