The fuel pump is designed to push fuel out of the tank and through the fuel line to the fuel injection. When the pump fails the engine will not start. Replacing the fuel pump involves taking the fuel tank down from the back of the vehicle and pulling the pump out of the tank.
Lower the fuel tank from the vehicle by unbolting the two straps securing the tank with a socket wrench. Place a jack under the tank and lower the jack halfway down to gain access to the wires and hoses.
Disconnect the fuel inlet hoses by loosening the hose clamp with a flat-tip screwdriver. Pull the inlet hose off the back of the fuel tank.
Disconnect the wires at the top of the tank by pulling up on the locking tab and pulling the connectors away from the tank. Unsnap the fuel line from the assembly by pulling the locking tabs up and pulling off the outlet line of the fuel pump housing.
Lower the tank to the ground. Drag the tank out from underneath the vehicle.
Unscrew the fuel pump housing at the top of the fuel tank with a large set of channel locks. Some applications have a tab that the channel locks cannot lock on to. Tap the tab with a hammer and a punch counterclockwise until it is loose enough to unscrew by hand.
Pull the assembly out of the tank. Take the fuel pump off the housing by pulling it away from the assembly.
Place the new fuel pump onto the assembly. Ensure the strainer is bolted on to the bottom of the pump.
Replace the O-ring around the top of the fuel tank. Slide the old O-ring off the threads of the tank and slide the new O-ring on to the tank.
Slide the tank under the vehicle and place on the jack. Raise the jack far enough up to install the inlet hose and electrical connectors.
Push the inlet hose onto the back of the fuel tank. Tighten the hose clamp with a flat-tip screwdriver to tighten the hose to the pipe.
Push the electrical connectors together until they lock in place. Check above where the gas tank is mounted to ensure there are no obstructions before raising the tank. Push the fuel line on to the outlet pipe of the fuel pump assembly.
Raise the tank to the bottom of the vehicle. Tighten the straps to secure the tank with a socket wrench.
Pour fuel in the fuel tank. The engine is ready to be started.
Start the engine to ensure the fuel pump is functioning correctly. Inspect for any leaks.
