Easy step by step instructions on how to replace an automotive fuel pump P0230,
P0231, P0232 and P0233, though appearances will vary the process is the same on
Difficulty Scale: 5 of 10
Tools and Supplies Needed
- Fuel siphon hose
- Fuel containers large enough to hold the amount of gas in the tank.
- Wrench set
- Socket set
- Fuel pump replacement
- Shop towels
- Protective eye wear and clothing
- Fuel filter
- Fuel line removal tool
- Fuel tank support
Begin with the vehicle safety raised in the air enough to access the fuel tank.
Use jack stands for additional safety. (No smoking or open flame.)
- Disconnect the negative battery terminal, this will avoid sparks
while working with a flammable liquid. (Note: Record pre-set radio stations so they
can be re-entered when the job is complete.)
Disconnecting Negative Battery Terminal
Step 2 - After the battery has been disconnected,
remove the gas cap and insert a hard plastic line into the filler neck to draw the
fuel out. There are a number of methods to perform this by causing a siphon. Once
the gas has started flowing keep the container below the level of the tank. (Note:
Gasoline and the fumes are highly flammable, so use appropriate precautions.)
Step 3 - Locate and remove gas tank filler neck
Gas Siphon with Gas Can
Remove Filler Neck Mounting Bolts
Step 4 - Once the filler neck mounting bolts have
been removed, locate and disconnect electrical connectors to fuel tank.
Step 5 - Next, locate and disconnect fuel line
using a fuel line removal tool. (Note: Needed for some models such as Ford.) Fuel
will leak at this point so be ready to use a fluid catch basin.
Disconnect Electrical Connectors
Disconnection Fuel Lines Using Removal Tool
Step 6 - After liquid fuel lines have been removed,
locate and disconnect fuel vapor lines form the fuel tank.
Step 7 - Some fuel vapor lines are held in place
by a retainer clip. Use a small screwdriver to release and remove the clip while
removing the line.
Removing Fuel Vapor Lines
Step 8 - Once all fuel lines have been released
from the tank, support the tank using a device. This can be done in a number of
ways, a fuel tank empty weighs about 30 to 40 pounds.
Fuel Line Retainer Clip
Step 9 - Locate and release tank holder supports,
There are two in most cases, at this point the tanks will become loose.
Fuel Tank Support Device
Step 10 - After the tanks mounts have been removed
the tank will become loose. Lower the tank and release top mounted fuel lines or
electrical connectors if any.
Release Fuel Tank Supports
Step 11 - Once the tank has been removed, disconnect
fuel lines from the fuel pump.
Removing Fuel Lines and Connectors
Step 12 - Next, remove fuel pump mounting bolts
which hold the pump to the fuel tank.
Fuel Line Release Tool
Step 13 - After the mounting bolts have been removed,
use a standard screwdriver to gently pry off the fuel pump cover or housing.
Removing Fuel Pump Mounting Bolts
Step 14 - Next, Release the fuel pump retainer
clips if any. Most models are designed with the fuel pump connected to the cover
Cover Removed Exposing Fuel Pump
Step 15 - Once the fuel pump retainer clip has
been released, gently lift the pump from the fuel tank. Most pump units incorporate
the fuel level sender as well.
Releasing Fuel Pump Retainer Clips
Step 16 - After the fuel pump has been removed
use a flashlight to inspect the tank for debris and clean as needed. (Note: A small
amount of debris is normal.)
Fuel Pump Removed
Step 17 - Next, match the failed pump to the replacement
pump, make sure all electrical and fuel line connections are the same. Clean mounting
surfaces using a shop towel and carburetor cleaner. Gently lower the replacement
pump into the fuel tank taking note on fuel level sender orientation.
Fuel Tank Inspection
Step 18 - Once the pump has been lowered into position
press the pump into place. Use any new O ring seals or gaskets provided with the
Installing New Fuel Pump
Step 19 - After the fuel pump is securely in place,
reinstall pump plate mounting bolts.
New Fuel Pump Installed
Step 20 - Then, tighten the fuel pump mounting
bolts using a star pattern to ensure a proper seal to the fuel tank.
Reinstalling Pump Plate Mounting Bolts
After completing these steps, reverse the order to reinstall the tank back into
the vehicle. It's best if a
Tighten Fuel Pump Mounting Bolts
is installed at the time of the new fuel pump assembly. Add gas to the
fuel tank before turning the ignition key, this will lubricate the pump.
Some manufacturers provide an access door to service the fuel pump, be sure to
research this information before beginning. To test for a fuel pump failure a
must be performed. Sometimes the the drive shaft must be removed
along with the fuel tank.
The automotive engine is designed to operate on a specific fuel system pressure
which is vital to engine performance
To maintain a constant pressure, the fuel
is located in the fuel tank and is comprised of an electric motor coupled
to a small internal vein style pump. Fuel pumps have a pressure relief valve that
allows fuel to bypass while recalculating inside the fuel tank. Direct injection
fuel pumps utilize an internal pressure regulator, while having only one liquid
fuel line routed to the engine as opposed to two, (pressure and return lines.)
When the ignition key is turned the fuel pump relay engages while supplying electrical
power to the pump. This relay is controlled by the main
detect engine rotation before signaling the relay. When servicing a truck fuel pump
there is the option to remove the bed to access the assembly.
- Replace the fuel filter
when replacing the pump, debris can be dislodged and enter the fuel filter during
a pump failure.
- Have a fire extinguisher available.
- Inspect fuel pump electrical connector for burns or heated spots and replace
if damaged. A
burned connector can cause the pump to intermittently fail.
- The fuel pump is controlled by a relay, this
relay should be tested to ensure proper operation.
- Do not remove tank unless empty or close to empty, a full gas tank is heavy
and can cause injury.
Article first published 2017-01-27