Replacing a bad Fuel Pump in a sedan requires a very detailed process, yet it can be carried out with the proper tools and knowledge. In a typical sedan, the process takes up to 3 to 5 hours, depending on the model of the car and the experience of the technician. First of all, one should disconnect the battery to avoid any electrical problem while repairing. A 2020 survey by the Automotive Service Association (ASA) indicated improper handling of electrical connections as responsible for 18 percent of post-repair failures on Fuel Pump replacement. Once the battery is disconnected, the fuel tank should be drained. Most sedentary cars have a fuel tank capacity ranging from 12 to 18 gallons, so this step could involve removing as much as 15 gallons of fuel, which can be heavy and challenging.
The next step is to detach the fuel tank from the vehicle. This involves removing bolts or screws holding the tank in place, which usually involves a torque of 20-40 ft-lbs depending on the model of the sedan. In most instances, however, the fuel tank is placed either underneath the rear seat or in the trunk area itself and requires removal of said components or access panel to be reached. For example, 2015 Toyota Camry needed a rear seat bottom cushion deleted for access to the Fuel Pump, while a 2017 Honda Accord had the needed trunk-mounted access panel for lowering the tank.
Once the tank is dropped, the faulty Fuel Pump is removed. The pump is usually mounted in a fuel pump module or sending unit and must be carefully disconnected. The assembly for the Fuel Pump typically includes the fuel level sensor, strainer, and pump motor. Replacement units are available from $100 to $400, depending on the make and model of the sedan. In some cases, aftermarket Fuel Pumps can offer a 20-40% cost savings compared to OEM parts.
After removing the old pump, the new one must be installed in reverse order. Ensure that the fuel lines and electrical connections are secure, as failure to do so can lead to fuel leaks or electrical failures. According to a report released in 2019, by the NHTSA, over 1,000 fuel-related recalls were pegged on bad connections and poor installation among other leading causes. If the new pump is tightly secured within the fuel chamber or at appropriate support, reconnect the fuel tank into the car while reconnecting all the lines on the car also.
Finally, the new Fuel Pump is to be tested by reconnecting the battery, turning the ignition to the “on” position without starting the engine, and looking for any fuel leaks. A pressure gauge can also be used to confirm that the fuel pressure is within the recommended range, typically between 40 and 60 psi. In case the pressure is very low, further investigation could be required because the malfunction may either be with the pump or the fuel filter.
It may cost anywhere between $300 and $800 for the whole repair process, depending on the specifications of the vehicle and labor rates in the area. Most repair shops provide a warranty for the new Fuel Pump. The standard warranty lasts anywhere between 1 to 3 years or 12,000 to 36,000 miles, depending on the type of warranty provided by the shops.