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How To Replace Fuel Tanks And Pumps

Your fuel system houses the life and blood of your vehicle. Unfortunately, the corrosive agents in fuel combined with the wear and tear that come with age can cause your tank and your pump to deteriorate. Thankfully, replacing both of these essential parts is easier than you think.



Parts you'll need:

  • Floor Jack
  • Jack Stands
  • Wrench Set
  • Brass Punch
  • Hammer
  • Suction Pump
  • Torque Wrench
  • 3/8 Ratchet
  • 3/8 Extension
  • 3/8 Socket Set (Comes with ratchet and extension)
  • Gasket Scraper
  • Fuel Tank
  • Fuel Tank Straps (only if required)
  • Fuel Pump
  • Fuel Pump Strainer
  • Fuel Filter
  • RTV Silicone



Before getting started

Here are a few precautionary steps have to be taken because you are working with fuel: 

-Make sure your work area is well ventilated 

-Keep a fire extinguisher handy 

-Do not smoke



Steps for removing and replacing the fuel tank:

  1. Remove the gas cap to relieve fuel tank pressure.
  2. Disconnect the negative battery cable.
  3. Siphon all remaining gasoline out of the tank and into a gas can.
  4. Raise and support the vehicle on jack stands.
  5. Disconnect the fuel filler tube.
  6. If you have an electric pump located in the fuel tank, disconnect the fuel pump harness now. You may need to remove the fuel tank shield, equipped on some models.
  7. Disconnect the fuel return and supply lines.
  8. Support the fuel tank.

IMPORTANT: If you have access to a transmission jack you can perform the job alone. If not, make sure you have a helper to support the fuel tank.

  1. Remove the fuel tank straps. Inspect the straps for any corrosion or damage, and replace if worn.
  2. Lower the fuel tank, and remove.
  3. Install new tank. Installation steps are the reverse of the removal process. 


Steps for installation of mechanical fuel pumps:


  1. Before you remove or disconnect any lines clean around the lines and the mounting flange. This will prevent any dirt from getting in.
  2. Remove the supply and replace the fuel lines.
  3. Cover the line ends after removal to prevent dirt from entering.
  4. Remove the flange bolts, once you have removed the fuel pump from the engine block, stuff a clean rag in the opening to prevent dirt from entering.


  1. Clean the mounting flange to remove dirt.
  2. Remove the rag.
  3. Apply a coat of RTV sealant on the new fuel pump gasket.
  4. Position the fuel pump flush with the block, and install and tighten the flange bolts.

IMPORTANT : Never force the pump with the flange bolts. If the fuel pump is not sitting flush with the block the rocker arm on the fuel pump is in the incorrect position. 

Ask a professional for torque specifications if you're not sure what torque to tighten the flange bolts.

  1. Make sure you remove the cover you placed over the ends earlier to keep the dirt out.
  2. Re-attach the fuel lines.. Start the engine and look for any leaks.