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Installation and fault finding
As gasoline is involved when working on the Fuel Pump, work in a ventilated area away from open flame.
- Relieve fuel system pressure before starting the replacement procedure, and refer to car maker’s instructions for specific steps.
- Drain tank, loosen tank straps and lower the tank; or locate the service hole in the boot; or disconnect the rear seat cushion (some vehicles have a removable access panel to the Fuel Pump module, allowing Fuel Pump replacement without removing the tank).
- Disconnect Fuel Pump module connector
- Disconnect fuel tank main tube
- Remove Fuel Pump module from fuel tank
- Remove fuel suction support
- Remove fuel pressure regulator if necessary
- Remove strainer
- Remove fuel suction plate and disconnect the Fuel Pump connector or wiring
- Remove Fuel Pump
For installation, perform the removal steps above in reverse order. To check for fuel leaks refer to the car maker’s instructions.
The most common cause of in-tank electric Fuel Pump failures is fuel tank contamination due to dirt and rust. Therefore it is essential that a replacement Fuel Pump should be installed into a clean fuel tank.
Another common cause of in-tank electric Fuel Pump failures is faulty electrical connections such as loose connections, poor grounds or low voltage to the pump due to overheated connectors.
- No initial combustion: No combustion occurs due to no operation or difficult start-up
- Stalling: Engine stalls shortly after startup due to no operation; or engine stalls when accelerator is depressed.
- Poor drivability: Hesitation during acceleration due to decreased flow quantity; insufficient output caused by no increase in fuel pressure; engine backfires; or abnormal knocking.
It is very important to make a correct diagnosis before installing a new Fuel Pump. This is because the real root cause might be another component than the Fuel Pump, such as a clogged strainer, contaminated fuel filter, faulty fuel gauges or even very low levels of fuel in the fuel tank. To help prevent Fuel tank problems:
- The Fuel Pump and fuel system should be maintained in good condition
- The vehicle should not be driven with a nearly empty fuel tank
- Attention should be paid to the fuel quality and octane level
- The fuel filter should be checked periodically and replaced before its service life is up
- Fuel hoses and electrical connections should be regularly checked for cracks, leaks and any other defects
- If the Fuel Pump needs to be replaced, ensure the fuel system is clean and the fuel tank is free from contaminants